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


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

Usage:

777E KDP
Off-Highway Truck/Tractor
777E (S/N: KDP1-UP; KDZ1-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

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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 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". 
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)
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(1) N = Normal, M = Monitor, A = Action

Engine

Cooling System

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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       
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(1) N = Normal, M = Monitor, A = Action
(2) Test for the pressure that is listed on the cap.

Fuel System

Reference: Refer to Testing & Adjusting, SENR9937, "Fuel System Pressure - Test" for more detail on the following test.

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Table 3
Status(1)  Description  Specification  Actual  Comments 
Lower Fuel Pressure Configuration 
  Fuel pressure at cranking speed (100 to 135 rpm )  75 kPa (11 psi)     
  Fuel pressure at low idle (700 to 900 rpm)  450 ± 50 kPa (65 ± 7 psi)     
  Fuel pressure at high idle (1800 to 2000 rpm)  500 ± 50 kPa (73 ± 7 psi)     
Higher Fuel Pressure Configuration 
  Fuel pressure at cranking speed (100 to 135 rpm)  75 kPa (11 psi)     
  Fuel pressure at low idle (700 to 900 rpm)  650 ± 50 kPa (94 ± 7 psi)     
  Fuel pressure at high idle (1800 to 2000 rpm)  705 ± 50 kPa (102 ± 7 psi)     
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(1) N = Normal, M = Monitor, A = Action

Lubrication System

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Table 4
Status(1)  Description  Specification  Actual  Comments 
  Engine Oil Pressure at Low Idle  138 kPa (20 psi)     
  Engine Oil Pressure  352 kPa (51 psi)     
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(1) N = Normal, M = Monitor, A = Action

Basic Engine

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Table 5
Status(1)  Description  Specification  Actual  Comments 
  Engine Speed at Low Idle  700 rpm     
  Engine Speed at High Idle  2250 rpm     
  Torque Converter Stall Test Engine RPM       
  Cylinder Cutout Test  -    Caterpillar Electronic Technician 
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(1) N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

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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)       
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(1) N = Normal, M = Monitor, A = Action
(2) Compare the exhaust temperature variance at each exhaust port.

Performance Checks

Operational Checks

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

Hydraulic System

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

Hoist Cylinder Performance - Test

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

Relief Valve (Hoist Dual Stage) - Test and Adjust

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

Relief Valve (Brake Oil Cooler) - Test and Adjust

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Table 10
Status(1)  Description  Specification  Actual  Comments 
  Brake Cooler Relief Valve Pressure at Low Idle  586 ± 14 kPa (85 ± 2 psi)     
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(1) N = Normal, M = Monitor, A = Action

Braking System

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

Service Brake Discs - Check

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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) 

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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) 
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(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

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Table 13
Status(1)  Description  Specification  Actual  Comments 
  Cut-in Pressure  758 kPa (110 psi)     
  Cut out Pressure  930 ± 35 kPa (135 ± 5 psi)     
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(1) N = Normal, M = Monitor, A = Action

Service Brakes and Retarder System Pressure - Test

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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)  4323 to 5702 kPa (627 to 825 psi)     
  Oil Pressure at the Front Slack Adjuster with Service Brake applied (if equipped) (Retarder Control Lever in OFF Position at High Idle)  7729 to 10195 kPa (1120 to 1480 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 864 kPa (95 to 125 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 864 kPa (95 to 125 psi)     
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(1) N = Normal, M = Monitor, A = Action

Slack Adjuster - Test and Adjust

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

Brake Cooling Pressure - Check

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

Power Train System

Reference: Refer to Testing & Adjusting, RENR8303, "Power Train" for more detail on the following test.

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

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Table 17
Status(1)  Description  Specification  Actual  Comments 
  Torque Converter Inlet Pressure at High Idle  930 ± 35 kPa (135 ± 5 psi)     
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(1) N = Normal, M = Monitor, A = Action

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

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Table 18
Status(1)  Description  Specification  Actual  Comments 
  Torque Converter Outlet Pressure at High Idle for trucks with dry front brakes  552 ± 70 kPa (80 ± 10 psi)     
  Torque Converter Outlet Pressure at High Idle for trucks with wet front brakes  758 ± 70 kPa (110 ± 10 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Pilot Control Pressure) - Test

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Table 19
Status(1)  Description  Specification  Actual  Comments 
  Relief Valve (Pilot Control Pressure  2760 ± 350 kPa (400 ± 50 psi)     
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(1) N = Normal, M = Monitor, A = Action

Transmission Lubrication Oil Pressure - Test

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Table 20
Status(1)  Description  Specification  Actual  Comments 
  Transmission Lubrication Relief Valve pressure in the NEUTRAL-1 position at Low Idle rpm  4.0 kPa (0.6 psi)     
  Transmission Lubrication Relief Valve pressure in the NEUTRAL-1 position at High Idle rpm  110 ± 30 kPa (16 ± 4 psi)     
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(1) N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pressure - Test and Adjust

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Table 21
Status(1)  Description  Specification  Actual  Comments 
  Torque Converter Lockup Clutch Pressure at Low Idle  2140 ± 70 kPa (310 ± 10 psi)     
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(1) N = Normal, M = Monitor, A = Action

Steering System

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

Relief Valve (Primary Steering Backup) - Test and Adjust

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Table 22
Status(1)  Description  Specification  Actual  Comments 
  Backup Relief Valve Pressure  26000 ± 400 kPa (3771 ± 58 psi)     
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(1) N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Pressure - Test and Adjust

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Table 23
Status(1)  Description  Specification  Actual  Comments 
  High Pressure Cut off Valve Pressure  21270 ± 350 kPa (3100 ± 50 psi)     
  Low Pressure Standby  2510 ± 440 kPa (364 ± 64 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Secondary Steering Backup) - Test and Adjust

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Table 24
Status(1)  Description  Specification  Actual  Comments 
  Secondary Steering Backup Relief Valve Pressure  20700 ± 400 kPa (3002 ± 58 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Secondary Steering Main) - Test and Adjust

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Table 25
Status(1)  Description  Specification  Actual  Comments 
  Secondary Steering Main Relief Valve Pressure  17225 ± 350 kPa (2498 ± 51 psi)     
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(1) N = Normal, M = Monitor, A = Action

Pressure Reducing Valve (Steering) - Test

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Table 26
Status(1)  Description  Specification  Actual  Comments 
  Pressure Reducing Valve Pressure  2600 + 500 - 200 kPa (377 + 73 - 29 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Steering Cylinder) - Test

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Table 27
Status(1)  Description  Specification  Actual  Comments 
  Steering Cylinder Relief Valve Pressure  27200 ± 690 kPa (3945 ± 100 psi)     
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(1) N = Normal, M = Monitor, A = Action

S.O.S

Reference: Refer to Operation and Maintenance Manual, SEBU9388, "Maintenance Interval Schedule" for more detail on performing S.O.S. samples.

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Table 28
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     
Show/hide table
(1) N = Normal, M = Monitor, A = Action

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