773E Off-Highway Truck TA2 Technical Inspection {0372, 0374, 1000, 7000, 753T, 7565} Caterpillar

Off-Highway Truck/Tractor

773E (S/N: PRB1-UP; ASK1-UP; DJS1-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.

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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 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 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, UENR3378, "Electric Starting System" for S/N:PRB1-UP and ; S/N:DJS1-UP machines and Testing and Adjusting, SENR1018, "Electric Starting System" for S/N:ASK1-UP machines.
		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 at low idle	538 kPa (78 psi)
	Fuel Pressure at high idle	641 kPa (93 psi)

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

Lubrication System

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)

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

Basic Engine

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

(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	11 seconds
	Rear Suspension Collapsed Pin to Pin Length (Approximate)(2)	887 mm (35 inch)
	Front Suspension Collapsed Chrome length (Approximate)(2)	21 mm (0.83 inch)
	Toe Out Measurement	58.7 mm (2.31 inch)

(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, KENR8732, "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	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
	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

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

Reference: Refer to Testing & Adjusting, KENR8335, "Air System and Brakes" for more detail on the following test.

Parking Brake System Pressure - Test and Adjust

Table 11

Status(1)	Description	Specification	Actual	Comments
	Parking Brake System Pressure	3170 ± 200 kPa (460 ± 29 psi)

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

Air Compressor and Governor - Test and Adjust

Table 12

Status(1)	Description	Specification	Actual	Comments
	Cut-in Pressure	655 kPa (95 psi)
	Cut out Pressure	830 ± 35 kPa (120 ± 5 psi)

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

Service Brake Discs - Check

Table 13

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 14

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 15

Status(1)	Description	Specification	Actual	Comments
	Oil Pressure at the Rear Slack Adjuster (Retarder Control Lever in ON Position at High Idle)	3650 kPa (530 psi) maximum
	Oil Pressure to the Front Brakes (Retarder Control Lever in ON Position at High Idle)	0 kPa (0 psi)
	Air Pressure at the Rear Air/Hydraulic Cylinder (Retarder Control Lever in ON Position at High Idle)	550 kPa (80 psi)
	Air Pressure at the Front Air/Hydraulic Cylinder (Retarder Control Lever in ON Position at High Idle)	0 kPa (0 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 Brakes (Retarder Control Lever in OFF Position at High Idle)	15065 to 19030 kPa (2185 to 2760 psi)
	Air Pressure at the Rear Air/Hydraulic Cylinder 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 Front Air/Hydraulic Cylinder 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 16

Status(1)	Description	Specification	Actual	Comments
	Residual Pressure at the Rear Wheels	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 17

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

Reference: Refer to Testing & Adjusting, KENR8332, "Power Train" for more detail on the following test.

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

Table 18

Status(1)	Description	Specification	Actual	Comments
	Gear Pump (Power Train Charging) Pressure at Low Idle	2480 kPa (360 psi)
	Gear Pump (Power Train Charging) Pressure at High Idle	3445 kPa (500 psi)

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

Torque Converter Lockup Clutch Supply Pressure - Test and Adjust

Table 19

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 20

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 21

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Maximum Pressure at Medium Idle	2065 ± 70 kPa (300 ± 10 psi)

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

Torque Converter Lockup Clutch Primary Pressure - Test and Adjust

Table 22

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

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

Table 23

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Inlet Pressure at High Idle	955 ± 95 kPa (139 ± 14 psi)

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

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

Table 24

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Outlet Pressure at High Idle	414 ± 34 kPa (60 ± 5 psi)

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

Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust

Table 25

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	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 26

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 27

Shims for the Pressure Control Valve Pressure Change Per Shim
Station (1)	A	B	C	E	F	G	H
Engaged Clutch	4	2	1	5	6	7	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)	Valve location (D) is not used.

Transmission Hydraulic Control Clutch Pressure - Test

Table 28

Clutch Pressure (High Idle)
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 29

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

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

Steering System

Reference: Refer to Testing & Adjusting, KENR8341, "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 Cut off Valve Pressure	21200 ± 350 kPa (3075 ± 50 psi)
	Low-Pressure Standby	3170 kPa (460 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 (2500 ± 50 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 kPa (3945 psi)

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

S.O.S

Reference: Refer to Operation and Maintenance Manual, SEBU8394, "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