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

Off-Highway Truck:

777D (S/N: FKR1-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.

2. Save the document as an HTML format.

3. 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 Testing and Adjusting, SENR1123, "Electric Starting System".
		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	415 to 450 kPa (60 to 65 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status (1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	172 kPa (25 psi) to 234 kPa (34 psi)
	Engine Oil Pressure	358 kPa (52 psi) to 600 kPa (87 psi)

( 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	1605 ± 65 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
	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
	Rear Suspension Collapsed Pin to Pin Length (Approximate) (2)	915 mm (36 inch)
	Front Suspension Collapsed Exposed Chrome length (Approximate) (2)	8 mm (0.31 inch)
	Toe Out Measurement	64.26 mm (2.53 inch)

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

Hydraulic System

ReferenceRefer to Testing & Adjusting, RENR8439, "Hydraulic System" for more detail on the following test.

Hoist Cylinder Performance - Test

Table 8

Acceptable Cylinder Drift
Status (1)	Minutes	Oil Temperature	Cylinder Drift	Actual	Comments
	7.0	338° 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 Dual Stage) - Test and Adjust

Table 9

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Test ((High Pressure) Engine at High Idle, Dump Body Fully RAISED)	18950 + 520 - 0 kPa (2750 + 75 - 0 psi)
	Relief Valve Test (Low Pressure) Engine at High Idle, Hoist Control Lever in the LOWER position)	3450 ± 350 kPa (500 ± 51 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Brake Oil Cooler) - Test and Adjust

Table 10

Status (1)	Description	Specification	Actual	Comments
	Brake Cooler Relief Valve Pressure at Low Idle	586 ± 14 kPa (85 ± 2 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Braking System

ReferenceRefer to Testing & Adjusting, RENR8430, "Air System and Brakes" for more detail on the following test.

Service Brake Discs - Check

Table 11

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 12

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.

Air Compressor and Governor - Test and Adjust

Table 13

Status (1)	Description	Specification	Actual	Comments
	Cut-in Pressure	655 kPa (95 psi)
	Cut out Pressure	830 ± 35 kPa (120.38320 ± 5.07640 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Service Brakes and Retarder System Pressure - Test

Table 14

Status (1)	Description	Specification	Actual	Comments
	Oil Pressure at the Rear Slack Adjuster (Retarder Control Lever in ON Position at High Idle)	3640 kPa (528 psi) maximum
	Oil Pressure at the Front Slack Adjuster (if equipped) (Retarder Control Lever in ON Position at High Idle)	6509 kPa (944 psi) maximum
	Oil Pressure to the Front Caliper Service Brakes (Retarder Control Lever in ON Position at High Idle)	0 kPa (0 psi)
	Air Pressure at the Air/Hydraulic Cylinder for the Rear Brakes (Retarder Control Lever in ON Position at High Idle)	550 kPa (80 psi)
	Air Pressure at the Air/Hydraulic Cylinder for the Front Caliper Service Brakes (Retarder Control Lever in ON Position at High Idle)	0 kPa (0 psi)
	Air Pressure at the Air/Hydraulic Cylinder for the Front Oil Cooled Brakes (Retarder Control Lever in ON Position at High Idle)	550 kPa (80 psi)
	Oil Pressure at the Rear Slack Adjuster with Service Brake applied (Retarder Control Lever in OFF Position at High Idle)	4345 to 5445 kPa (630 to 790 psi)
	Oil Pressure at the Front Slack Adjuster with Service Brake applied (if equipped) (Retarder Control Lever in OFF Position at High Idle)	7722 to 9756 kPa (1120 to 1415 psi)
	Oil Pressure to the Front Caliper Service Brakes with Service Brake applied (Retarder Control Lever in OFF Position at High Idle)	19822 kPa (2875 psi)
	Air Pressure at the Air/Hydraulic Cylinder for the Rear Brakes with Service Brake applied (Retarder Control Lever in OFF Position at High Idle)	655 to 827 kPa (95 to 120 psi)
	Air Pressure at the Air/Hydraulic Cylinder for the Front Brakes with Service Brake applied (Retarder Control Lever in OFF Position at High Idle)	655 to 827 kPa (95 to 120 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Slack Adjuster - Test and Adjust

Table 15

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

( 1 )

N = Normal, M = Monitor, A = Action

Brake Cooling Pressure - Check

Table 16

Status (1)	Description	Specification	Actual	Comments
	Brake Cooling Pressure at LOW IDLE	14 kPa (2 psi)
	Brake Cooling Pressure at HIGH IDLE	172 kPa (25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, RENR8427, "Power Train" for more detail on the following test.

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

Table 17

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Inlet Pressure at High Idle	930 ± 35 kPa (135 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

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

Table 18

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Outlet Pressure at High Idle	450 ± 70 kPa (65 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Lubrication Oil Pressure - Test

Table 19

Status (1)	Description	Specification	Actual	Comments
	Transmission Lubrication Relief Valve pressure in the NEUTRAL-1 position at Low Idle rpm	4 kPa (0.6 psi)
	Transmission Lubrication Relief Valve pressure in the NEUTRAL-1 position at High Idle rpm	70 to 135 kPa (10 to 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Supply Pressure - Test and Adjust

Table 20

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Supply Pressure at Low Idle	4690 ± 200 kPa (680 ± 29 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pilot Pressure - Test and Adjust

Table 21

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 Maximum Pressure - Test

Table 22

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Maximum Pressure at Medium Idle	2140 ± 70 kPa (310 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Primary Pressure - Test and Adjust

Table 23

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Primary Pressure at Low Idle	1030 ± 35 kPa (150 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Gear Pump (Transmission) Pressure - Test and Adjust

Table 24

Status (1)	Description	Specification	Actual	Comments
	Gear Pump (Transmission) Pressure at Low Idle	2480 kPa (360 psi)
	Gear Pump (Transmission) Pressure at High Idle	3200 kPa (465 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Pilot Pressure - Test and Adjust

Table 25

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

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust

Table 26

Primary Clutch Pressure
Station (1)		"A"	"B"	"C"	"E"	"F"	"G"	"H"
Clutch		No. 4	No. 2	No. 1	No. 5	No. 6	No. 7	No. 3
Speed Position	Engaged Clutches	Pressure	Pressure	Pressure	Pressure	Pressure	Pressure	Pressure
NEUTRAL-1	1	0	0	345 kPa (50 psi) (2)	0	0	0	0
NEUTRAL-2	1	0	0	345 kPa (50 psi) (2)	0	0	0	0
REVERSE	1 and 7	0	0	345 kPa (50 psi) (2)	0	0	415 kPa (60 psi) (2)	0
FIRST	2 and 6	0	275 kPa (40 psi) (2)	0	0	415 kPa (60 psi) (2)	0	0
SECOND	1 and 6	0	0	345 kPa (50 psi) (2)	0	415 kPa (60 psi) (2)	0	0
THIRD	3 and 6	0	0	0	0	415 kPa (60 psi) (2)	0	550 kPa (80 psi) (2)
FOURTH	1 and 5	0	0	345 kPa (50 psi) (2)	345 kPa (50 psi) (2)	0	0	0
FIFTH	3 and 5	0	0	0	345 kPa (50 psi) (2)	0	0	550 kPa (80 psi) (2)
SIXTH	1 and 4	515 kPa (75 psi) (2)	0	345 kPa (50 psi) (2)	0	0	0	0
SEVENTH	3 and 4	515 kPa (75 psi) (2)	0	0	0	0	0	550 kPa (80 psi) (2)

( 1 )	Station "D" is not used.
( 2 )	The tolerance is ± 40 kPa (± 6 psi).

Table 27

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	2.54 mm (0.100 inch)	2.54 mm (0.100 inch)	2.54 mm (0.100 inch)	4.58 mm (0.180 inch)	4.58 mm (0.180 inch)	4.58 mm (0.180 inch)	4.58 mm (0.180 inch)
Color of the Outer Spring of the Load Piston	Light Blue	Yellow	Light Green	Yellow	Yellow	Light Green	Light Green
Color of the Inner Spring of the Load Piston	Yellow	Light Blue	Light Blue	Light Blue	Light Blue	Yellow	Orange
Size of the Decay Orifice	1.57 mm (0.062 inch)	1.19 mm (0.047 inch)	-	1.57 mm (0.062 inch)	1.57 mm (0.062 inch)	-	1.40 mm (0.055 inch)
Color of the Decay Orifice	Green	Blue	-	Green	Green	-	Yellow
Overall Length of the Load Piston	58.5 mm (2.30 inch)	51.5 mm (2.03 inch)	51.5 mm (2.03 inch)	51.5 mm (2.03 inch)	51.5 mm (2.03 inch)	51.5 mm (2.03 inch)	58.5 mm (2.30 inch)

( 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 28

(7) Shims for the Pressure Control Valve
Valve Location (1)	A	B	C	E	F	G	H
Clutch that is engaged	4	2	1	5	6	7	3
The thickness of the shim	Pressure Change	Pressure Change	Pressure Change	Pressure Change	Pressure Change	Pressure Change	Pressure Change
5J-2721 Shim
0.13 mm (.005 inch)	13 kPa (1.9 psi)	16 kPa (2.4 psi)	20 kPa (2.9 psi)	17 kPa (2.4 psi)	17 kPa (2.4 psi)	18 kPa (2.7 psi)	18 kPa (2.6 psi)
6J-3993 Shim
0.25 mm (.010 inch)	26 kPa (3.8 psi)	33 kPa (4.8 psi)	41 kPa (5.9 psi)	33 kPa (4.8 psi)	33 kPa (4.8 psi)	37 kPa (5.4 psi)	35 kPa (5.1 psi)
4M-1751 Spacer
0.40 mm (0.016 inch)	42 kPa (6.1 psi)	53 kPa (7.7 psi)	65 kPa (9.4 psi)	53 kPa (7.7 psi)	53 kPa (7.7 psi)	59 kPa (8.6 psi)	56 kPa (8.2 psi)
5J-1036 Shim
0.80 mm (0.032 inch)	84 kPa (12.2 psi)	103 kPa (15.0 psi)	126 kPa (18.2 psi)	103 kPa (15.0 psi)	103 kPa (15.0 psi)	114 kPa (16.6 psi)	109 kPa (15.8 psi)

( 1 )

Valve location (D) is not used.

Transmission Hydraulic Control Clutch Pressure - Test

Table 29

Clutch Pressure
Station (1)			"A"	"B"	"C"	"E"	"F"	"G"	"H"
Clutch			No. 4	No. 2	No. 1	No. 5	No. 6	No. 7	No. 3
Speed Pos.	Engaged Clutches	Gov. Setting	psi	psi	psi	psi	psi	psi	psi
NEUTRAL-1	1	Low Idle	0	0	2780 kPa (403 psi) (2)	0	0	0	0
		High Idle	0	0	2880 kPa (418 psi) (3)	0	0	0	0
NEUTRAL-2	1	Low Idle	0	0	2780 kPa (403 psi) (2)	0	0	0	0
		High Idle	0	0	2880 kPa (418 psi) (3)	0	0	0	0
REVERSE	1 and 7	Low Idle	0	0	2780 kPa (403 psi) (2)	0	0	2760 kPa (400 psi) (2)	0
		High Idle	0	0	2880 kPa (418 psi) (3)	0	0	2760 kPa (400 psi) (2)	0
FIRST	2 and 6	Low Idle	0	2365 kPa (343 psi) (2)	0	0	2515 kPa (365 psi) (2)	0	0
		High Idle	0	2365 kPa (343 psi) (2)	0	0	2515 kPa (365 psi) (2)	0	0
SECOND	1 and 6	Low Idle	0	0	N/A	0	N/A	0	0
		High Idle	0	0	2880 kPa (418 psi) (3)	0	2515 kPa (365 psi) (2)	0	0
THIRD	3 and 6	Low Idle	0	0	0	0	N/A	0	N/A
		High Idle	0	0	0	0	2515 kPa (365 psi) (2)	0	1825 kPa (265 psi) (2)
FOURTH	1 and 5	Low Idle	0	0	N/A	N/A	0	0	0
		High Idle	0	0	2880 kPa (418 psi) (3)	2435 kPa (353 psi) (2)	0	0	0
FIFTH	3 and 5	Low Idle	0	0	0	N/A	0	0	N/A
		High Idle	0	0	0	2435 kPa (353 psi) (2)	0	0	1825 kPa (265 psi) (2)
SIXTH	1 and 4	Low Idle	N/A	0	N/A	0	0	0	0
		High Idle	1425 kPa (207 psi) (2)	0	2880 kPa (418 psi) (3)	0	0	0	0
SEVENTH	3 and 4	Low Idle	N/A	0	0	0	0	0	N/A
		High Idle	1425 kPa (207 psi) (2)	0	0	0	0	0	1825 kPa (265 psi) (2)

( 1 )	Station "D" is not used.
( 3 )	Tolerance is ± 228 kPa (33 psi).
( 2 )	Tolerance is + 240 kPa (35 psi) or − 100 kPa (15 psi).

Steering System

ReferenceRefer to Testing & Adjusting, RENR8436, "Steering System" for more detail on the following test.

Relief Valve (Primary Steering Backup) - Test and Adjust

Table 30

Status (1)	Description	Specification	Actual	Comments
	Backup Relief Valve Pressure	26000 ± 400 kPa (3771 ± 58 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Pressure - Test and Adjust

Table 31

Status (1)	Description	Specification	Actual	Comments
	High Pressure Cutoff Valve Pressure	21270 ± 350 kPa (3100 ± 50 psi)
	Low Pressure Standby	2510 ± 440 kPa (364 ± 64 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Secondary Steering Backup) - Test and Adjust

Table 32

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 33

Status (1)	Description	Specification	Actual	Comments
	Secondary Steering Main Relief Valve Pressure	17225 ± 350 kPa (2498 ± 51 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Pressure Reducing Valve (Steering) - Test

Table 34

Status (1)	Description	Specification	Actual	Comments
	Pressure Reducing Valve Pressure	2600 + 500 - 200 kPa (377 + 73 - 29 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering Cylinder) - Test

Table 35

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

( 1 )

N = Normal, M = Monitor, A = Action

S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU8308, "Maintenance Interval Schedule" for more detail on performing S.O.S. samples.

Table 36

Status (1)	Description	Obtain		Comments
	Engine Oil Sample
	Cooling System Coolant Sample (Level)
	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