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

Quarry Truck:

775E (S/N: BEC1-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, SENR1018, "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		For fan drive. Alternator and air conditioner belts should deflect 13 to 19 mm (0.5 to 0.7 inch).
	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	489 + 195 - 147 kPa (71 + 28 - 21 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status (1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	151 + 449 - 51 kPa (22 + 65 - 7 psi)
	Engine Oil Pressure at High Idle	357 + 243 - 82 kPa (52 + 35 - 12 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Basic Engine

Table 5

Status (1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle	650 ± 10 rpm
	Engine Speed at High Idle	2100 ± 10 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	97.1 ± 14.6 kPa (14.1 ± 2.1 psi)
	Engine Speed	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	11 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	58.7 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, RENR6516, "Hydraulic System" 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 (0.250 inch)
	4.1	49° to 64°C (120° to 149°F)	6.35 mm (0.250 inch)
	3.0	65° C (150° F)	6.35 mm (0.250 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Hoist Dual Stage) - 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

Relief Valve (Rear Brake Oil Cooler) - Test and Adjust

Table 10

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Pressure	586 ± 14 kPa (85 ± 2 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, RENR6509, "Power Train System" for more detail on the following test.

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

Table 11

Status (1)	Description	Specification	Actual	Comments
	Relief Vale Pressure at Engine Speed of 1922 ± 65 RPM	414 ± 34 kPa (60 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

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

Table 12

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Pressure at HIGH IDLE	Less than 955 ± 95 kPa (139 ± 14 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Supply Pressure - Test

Table 13

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Supply Pressure at LOW IDLE	2790 ± 35 kPa (405 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pilot Pressure - Test and Adjust

Table 14

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Pilot Pressure at LOW IDLE	1725 ± 70 kPa (250 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Leakage - Test

Table 15

Status (1)	Description	Specification	Actual	Comments
	Maximum flow rate	3.8 L/min (1 US gpm)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Maximum Pressure - Test

Table 16

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Maximum Pressure at LOW IDLE	1720 ± 70 kPa (249 ± 10 psi) (2)
		2065 ± 70 kPa (300 ± 10 psi) (3)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	for 775E S/N:BEC1-261
( 3 )	for 775E S/N:BEC262-UP

Torque Converter Lockup Clutch Primary Pressure - Test and Adjust

Table 17

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Primary Pressure at LOW IDLE	960 ± 35 kPa (139 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

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

Table 18

Status (1)	Description	Specification	Actual	Comments
	Gear Pump Pressure at LOW IDLE	2480 kPa (360 psi) minimum
	Gear Pump Pressure at HIGH IDLE	3445 kPa (500 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust

Table 19

Primary Clutch Pressure
Station (1)		"A"	"B"	"C"	"E"	"F"	"G"	"H"
Clutch		No. 2	No. 1	No. 7	No. 5	No. 4	No. 6	No. 3
Speed Position	Engaged Clutches	Pressure	Pressure	Pressure	Pressure	Pressure	Pressure	Pressure
NEUTRAL	4					300 ± 20 kPa (44 ± 3 psi)
REVERSE	1 and 7		315 ± 20 kPa (46 ± 3 psi)	315 ± 20 kPa (46 ± 3 psi)
FIRST	1 and 6		315 ± 20 kPa (46 ± 3 psi)				315 ± 20 kPa (46 ± 3 psi)
SECOND	3 and 6						315 ± 20 kPa (46 ± 3 psi)	330 ± 20 kPa (48 ± 3 psi)
THIRD	2 and 6	440 ± 20 kPa (64 ± 3 psi)					315 ± 20 kPa (46 ± 3 psi)
FOURTH	3 and 5				310 ± 20 kPa (45 ± 3 psi)			330 ± 20 kPa (48 ± 3 psi)
FIFTH	2 and 5	440 ± 20 kPa (64 ± 3 psi)			310 ± 20 kPa (45 ± 3 psi)
SIXTH	3 and 4					300 ± 20 kPa (44 ± 3 psi)		330 ± 20 kPa (48 ± 3 psi)
SEVENTH	2 and 4	440 ± 20 kPa (64 ± 3 psi)				300 ± 20 kPa (44 ± 3 psi)

( 1 )

Station "D" is not used.

Table 20

Specifications And Identification Of The Components Of The Pressure Control Valve
Location of the Load Piston Body (1)	A	B	C	E	F	G	H
Thickness of the Load Piston Orifice	4.58 mm (0.180 inch)	4.58 mm (0.180 inch)	6.60 mm (0.260 inch)	2.54 mm (0.100 inch)	4.58 inch (0.180 inch)	6.60 mm (0.260 inch)	4.58 mm (0.180 inch)
Color of the Outer Spring of the Load Piston	Light blue color	Light green color	Light green color	Light blue color	Light blue color	Light green color	Yellow color
Color of the Inner Spring of the Load Piston	Light green color	Light blue color	Light blue color	Light blue color	Light blue color	Light blue color	Light blue color
Size of the Decay Orifice	1.57 mm (0.062 inch)	1.57 mm (0.062 inch)	1.40 mm (0.055 inch)	1.57 mm (0.062 inch)	1.57 mm (0.062 inch)	1.57 mm (0.062 inch)	1.57 mm (0.062 inch)
Color of the Decay Orifice	Green color	Green color	Yellow color	Green color	Green color	Green color	Green color

( 1 )

The location of the load piston body is identical to the location of the station for the valve. Station "D" is not used.

Table 21

Shims For The Pressure Control Valve Pressure Change Per Shim
Station (1)	A	B	C	E	F	G	H
Engaged Clutch	2	1	7	5	4	6	3
Thickness of Shim	Pressure Change	Pressure Change	Pressure Change	Pressure Change	Pressure Change	Pressure Change	Pressure Change
5J-2721 Shim
0.13 mm (0.005 inch)	14 kPa (2.0 psi)	20 kPa (2.9 psi)	20 kPa (2.9 psi)	15 kPa (2.2 psi)	15 kPa (2.2 psi)	20 kPa (2.9 psi)	17 kPa (2.5 psi)
6J-3993 Shim
0.25 mm (0.010 inch)	28 kPa (4.1 psi)	41 kPa (5.9 psi)	41 kPa (5.9 psi)	30 kPa (4.4 psi)	30 kPa (4.4 psi)	41 kPa (5.9 psi)	33 kPa (4.8 psi)
4M-1751 Spacer
0.41 mm (0.016 inch)	45 kPa (6.5 psi)	65 kPa (9.4 psi)	65 kPa (9.4 psi)	48 kPa (7.0 psi)	48 kPa (7.0 psi)	65 kPa (9.4 psi)	53 kPa (7.7 psi)
5J-1036 Shim
0.80 mm (0.031 inch)	87 kPa (12.6 psi)	125 kPa (18.2 psi)	125 kPa (18.2 psi)	92 kPa (13.3 psi)	92 kPa (13.3 psi)	125 kPa (18.2 psi)	103 kPa (14.9 psi)

( 1 )

Station "D" is not used.

Transmission Hydraulic Control Clutch Pressure - Test

Table 22

Clutch Pressure
Station (1)		"A"	"B"	"C"	"E"	"F"	"G"	"H"
Clutch		No. 2	No. 1	No. 7	No. 5	No. 4	No. 6	No. 3
Speed Position	Engaged Clutches	Pressure	Pressure	Pressure	Pressure	Pressure	Pressure	Pressure
NEUTRAL	4					2240 ± 125 kPa (325 ± 18 psi)
REVERSE	1 and 7		2940 ± 165 kPa (426 ± 24 psi)	2940 ± 165 kPa (426 ± 24 psi)
FIRST	1 and 6		2940 ± 165 kPa (426 ± 24 psi)				2940 ± 165 kPa (426 ± 24 psi)
SECOND	3 and 6						2940 ± 165 kPa (426 ± 24 psi)	2480 ± 140 kPa (360 ± 20 psi)
THIRD	2 and 6	2265 ± 115 kPa (329 ± 17 psi)					2940 ± 165 kPa (426 ± 24 psi)
FOURTH	3 and 5				2250 ± 125 kPa (326 ± 18 psi)			2480 ± 140 kPa (360 ± 20 psi)
FIFTH	2 and 5	2265 ± 115 kPa (329 ± 17 psi)			2250 ± 125 kPa (326 ± 18 psi)
SIXTH	3 and 4					2240 ± 125 kPa (325 ± 18 psi)		2480 ± 140 kPa (360 ± 20 psi)
SEVENTH	2 and 4	2265 ± 115 kPa (329 ± 17 psi)				2240 ± 125 kPa (325 ± 18 psi)

( 1 )

Station "D" is not used.

Transmission Hydraulic Control Pilot Pressure - Test and Adjust

Table 23

Status (1)	Description	Specification	Actual	Comments
	Transmission Hydraulic Control Pilot Pressure	1755 ± 35 kPa (255 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering System

ReferenceRefer to Testing & Adjusting, RENR6511, "Steering System" for more detail on the following test.

Relief Valve (Primary Steering Backup) - Test and Adjust

Table 24

Status (1)	Description	Specification	Actual	Comments
	Back up Relief Valve Pressure for the Primary Steering at LOW IDLE	26000 ± 400 kPa (3771 ± 58 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Pressure - Test and Adjust

Table 25

Status (1)	Description	Specification	Actual	Comments
	Cutoff Pressure (Pressure Compensator Valve)	21200 ± 350 kPa (3075 ± 50 psi)
	Low Pressure Standby (Pressure Compensator Valve)	3170 to 4800 kPa (460 to 695 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Secondary Steering Backup) - Test and Adjust

Table 26

Status (1)	Description	Specification	Actual	Comments
	Secondary Steering Backup Relief Valve Pressure	20700 ± 400 kPa (3002 ± 58 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Secondary Steering Main) - Test and Adjust

Table 27

Status (1)	Description	Specification	Actual	Comments
	Secondary Steering Main Relief Valve Pressure	17225 ± 350 kPa (2500 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Pressure Reducing Valve (Steering) - Test

Table 28

Status (1)	Description	Specification	Actual	Comments
	Pressure Reducing Valve Pressure	2600 + 500 - 200 kPa (377 + 73 - 30 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering Cylinder) - Test

Table 29

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

( 1 )

N = Normal, M = Monitor, A = Action

Braking System

ReferenceRefer to Testing & Adjusting, RENR6513, "Air System and Brakes" for more detail on the following test.

Service Brake Discs - Check

Table 30

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 31

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 32

Status (1)	Description	Specification		Actual	Comments
		Retarder Control Lever Full ON	Retarder Control Lever Full OFF
	Oil Pressure at Rear Slack Adjuster	3650 kPa (530 psi)	4345 to 5445 kPa (630 to 790 psi)
	Oil Pressure at Front Brakes	0	15065 to 19030 kPa (2185 to 2760 psi)
	Air Pressure at Rear Brake Master Cylinder	550 kPa (80 psi)	655 to 827 kPa (95 to 120 psi)
	Air Pressure at Front Brake Master Cylinder	0	655 to 827 kPa (95 to 120 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Slack Adjuster - Test and Adjust

Table 33

Status (1)	Description	Specification	Actual	Comments
	Residual Pressure	0 to 127 kPa (0 to 18 psi)
	Force to move piston	220 N (50 lb)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Cooling Pressure - Check

Table 34

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

S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU7590, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Table 35

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