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773G and 775G Off-Highway Trucks TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar


773G and 775G Off-Highway Trucks TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565}

Usage:

773G LRC MWH
Quarry Truck
773G (S/N: MWH1-UP)
775G (S/N: RFM1-UP)

Introduction

Inspections are the most basic form of condition monitoring. They 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 effectively 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, SENR3581, "37-MT, 41-MT, and 42-MT Series Starting Motors". 
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

Reference: Refer to Testing & Adjusting, KENR9886, "C27 and C32 Engines for Caterpillar Built Machines" for more detail on the following test.

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

Fuel System

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Table 3
Status(1)  Description  Specification  Actual  Comments 
  Fuel System Pressure at Low Idle  650 ± 50 kPa (94 ± 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  -     
  Engine Oil Pressure at Full Load Speed (1800 rpm)  -     
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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 + 30 - 10 rpm     
  Engine Speed at High Idle  2285 ± 30 rpm     
  Torque Converter Stall Test Engine RPM  1831 rpm     
  Cylinder Cutout Test  -    Caterpillar Electronic Technician 
  Engine Crankcase Pressure (Blowby)  -     
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(1) N = Normal, M = Monitor, A = Action

Performance Checks

Operational Checks

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Table 6
Status(1)  Description  Specification  Actual  Comments 
  Raise the Dump Body  15 seconds     
  Front Suspension Group measurement  170 mm (6.7 inch)     
  Rear Suspension Group measurement from Pin to Pin  1015 ± 13 mm (40.0 ± 0.5 inch)     
  Toe Out Measurement  58.67 mm (2.31 inch)     
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(1) N = Normal, M = Monitor, A = Action

Hydraulic System

Reference: Refer to Testing & Adjusting, KENR9964, "773G and 775G Off-Highway Truck Hydraulic and Braking System" for more detail on the following test.

Service Brakes and Retarder System Pressure - Test

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Table 7
Status(1)  Description  Specification  Actual  Comments 
  Pressure at Slack Adjuster for Service Brakes (Retarder in OFF Position at Low Idle)  6070 ± 690 kPa (880 ± 100 psi)     
  Pressure at Front Pressure Tap for Service Brakes (Retarder in OFF Position at Low Idle)  8140 ± 690 kPa (1180 ± 100 psi)     
  Slack Adjuster for Service Brakes (Retarder in ON Position at Low Idle)  4965 ± 690 kPa (720 ± 100 psi)     
  Pressure at Front and Rear Pressure Tap for Service Brakes (Retarder in OFF Position at Low Idle)  Less than 138 kPa (20 psi)     
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(1) N = Normal, M = Monitor, A = Action

Secondary Brake System Pressure Test

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Table 8
Status(1)  Description  Specification  Actual  Comments 
  Secondary Brake pressure Test (Brakes are not applied, at Low Idle, in the Neutral position)  5035 ± 690 kPa (730 ± 100 psi)     
  Secondary Brake pressure Test (Secondary Brakes fully applied at Low Idle, in the Neutral position)  less than 138 kPa (20 psi)     
  Secondary Brake pressure Test (Brakes are not applied, engine off, in the Neutral position)  3800 kPa (550 psi) or above     
  Secondary Brake pressure Test (Secondary Brakes fully applied at Low Idle, in the Neutral position)  less than 138 kPa (20 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Hoist Raise, Hoist Lower) - 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 bed fully RAISED)  773G
17230 ± 520 kPa (2500 ± 75 psi) 		    
775G
18950 ± 520 kPa (2750 ± 75 psi) 		 
  Relief Valve Test (Low Pressure) Engine at high idle, Hoist control lever in the LOWER position)  3450 ± 350 kPa (500 ± 50 psi)     
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(1) N = Normal, M = Monitor, A = Action

Power Train System

Reference: Refer to Testing & Adjusting, KENR9958, "773G and 775G Off-Highway Truck Power Train" for more detail on the following test.

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

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Table 10
Status(1)  Description  Specification  Actual  Comments 
  Main Relief Valve Pressure at high idle in the NEUTRAL Position and Parking Brakes are Engaged. The lockup clutch is deactivated.  3100 kPa (450 psi) maximum     
  Main Relief Valve Pressure at low idle in the NEUTRAL Position and Parking Brakes are Engaged. The lockup clutch is deactivated.  2500 kPa (370 psi) minimum     
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(1) N = Normal, M = Monitor, A = Action

Transmission Lubrication Oil Pressure - Test

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Table 11
Status(1)  Description  Specification  Actual  Comments 
  Transmission lubrication Relief Valve pressure in the NEUTRAL position at low idle  10 kPa (1.5 psi) minimum     
  Transmission lubrication Relief Valve pressure in the NEUTRAL position at high idle  137 to 255172 kPa (20 to 37 psi)     
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(1) N = Normal, M = Monitor, A = Action

Transmission Pressures - Test and Adjust

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Table 12
Status(1)  Description  Specification  Actual  Comments 
  Clutch 1  Low Idle 2655 ± 172 kPa (385 ± 25 psi)
High Idle 3100 ± 138 kPa (450 ± 20 psi) 		    
  Clutch 2  Low Idle 1720 ± 69 kPa (250 ± 10 psi)
High Idle 1720 ± 69 kPa (250 ± 10 psi) 		    
  Clutch 3  Low Idle 2275 ± 69 kPa (330 ± 10 psi)
High Idle 2275 ± 69 kPa (330 ± 10 psi) 		    
  Clutch 4  Low Idle 1930 ± 69 kPa (280 ± 10 psi)
High Idle 1930 ± 69 kPa (280 ± 10 psi) 		    
  Clutch 5  Low Idle 2655 ± 172 kPa (385 ± 25 psi)
High Idle 3100 ± 138 kPa (450 ± 20 psi) 		    
  Clutch 6  Low Idle 2655 ± 172 kPa (385 ± 25 psi)
High Idle 3100 ± 138 kPa (450 ± 20 psi) 		    
  Clutch 7  Low Idle 2655 ± 172 kPa (385 ± 25 psi)
High Idle 3100 ± 138 kPa (450 ± 20 psi) 		    
  Transmission System Pressure  Low Idle 2655 ± 172 kPa (385 ± 25 psi)
High Idle 3100 ± 138 kPa (450 ± 20 psi) 		    
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(1) N = Normal, M = Monitor, A = Action

Steering System

Reference: Refer to Testing & Adjusting, KENR9966, "773G and 775G Off-Highway Truck Steering System" for more detail on the following test.

Control Manifold (Steering) - Test and Adjust

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Table 13
Status(1)  Description  Specification  Actual  Comments 
  Main Relief Valve Secondary Steering pressure at high idlePark position  26000 ± 400 kPa (3770 ± 58 psi)     
  Backup Relief Valve for Secondary Steering pressure at high idle in the Park position  20700 ± 400 kPa (3002 ± 58 psi)     
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(1) N = Normal, M = Monitor, A = Action

Piston Pump (Steering, Fan) - Test and Adjust

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Table 14
Status(1)  Description  Specification  Actual  Comments 
  High Pressure Cutoff Valve pressure at high idle  21200 ± 350 kPa (3075 ± 50 psi)     
  Low Pressure Standby (Pressure Compensator Valve)  3600 kPa (520 psi)     
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(1) N = Normal, M = Monitor, A = Action

S.O.S

Reference: Refer to Operation and Maintenance Manual, SEBU8547, "Maintenance Interval Schedule" for more detail on the following test.

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Table 15
Status(1)  Description  Obtain  Comments 
  Engine Coolant Sample (Level I)     
  Differential and Final Drive Oil Sample     
  Engine Oil Sample     
  Front Wheel Oil Sample     
  Hoist and Brake Tank Oil Sample     
  Steering System Oil Sample     
  Torque Converter and Transmission Oil Sample     
  Engine Coolant Sample (Level II)     
Show/hide table
(1) N = Normal, M = Monitor, A = Action

Caterpillar Information System:

Cat® Detect and Cat® MineStar System Onboard Configuration for the MS352 Satellite Receiver Binary Format
14M Series 3 Motor Grader Crankshaft Vibration Damper - Inspect
CP54B, CS54B and CS64B Vibratory Soil Compactors Propel System Axle - Rear (Without Brake)
966H and 972H Wheel Loaders Machine Systems Alternator
Installation of the 247-4472 Air Lines Group on Certain PM-201 Cold Planers{1071} Installation of the 247-4472 Air Lines Group on Certain PM-201 Cold Planers{1071}
259D, 279D, 289D, 299D, 299D XHP, 299D2 and 299D2 XHP Compact Track Loaders, 257D, 277D, 287D, 297D, 297D XHP, 297D2 and 297D2 XHP Multi Terrain Loaders and 236D, 242D, 246D, 262D, 272D, 272D XHP, 272D2 and 272D2 XHP Skid Steer Loaders High Flow Hydraulic System - Test and Adjust - If Equipped
239D and 249D Compact Track Loaders and 226D and 232D Skid Steer Loaders Accumulator (Ride Control) - Test and Charge
120 and 120 AWD Motor Grader Parking
259D, 279D, 289D, 299D, 299D XHP, 299D2 and 299D2 XHP Compact Track Loaders, 257D, 277D, 287D, 297D, 297D XHP, 297D2 and 297D2 XHP Multi Terrain Loaders and 236D, 242D, 246D, 262D, 272D, 272D XHP, 272D2 and 272D2 XHP Skid Steer Loaders Lines (Lift Cylinder)
259D, 279D, 289D, 299D, 299D XHP, 299D2 and 299D2 XHP Compact Track Loaders, 257D, 277D, 287D, 297D, 297D XHP, 297D2 and 297D2 XHP Multi Terrain Loaders and 236D, 242D, 246D, 262D, 272D, 272D XHP, 272D2 and 272D2 XHP Skid Steer Loaders Lines (Lift Cylinder)
824K Wheel Dozer, 825K Soil Compactor and 826K Landfill Compactor Machine Systems Push Button Switch
259D, 279D, 289D, 299D, 299D XHP, 299D2 and 299D2 XHP Compact Track Loaders, 257D, 277D, 287D, 297D, 297D XHP, 297D2 and 297D2 XHP Multi Terrain Loaders and 236D, 242D, 246D, 262D, 272D, 272D XHP, 272D2 and 272D2 XHP Skid Steer Loaders Lines (Lift Cylinder)
773G and 775G Off-Highway Trucks TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565} 773G and 775G Off-Highway Trucks TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565}
773E Off-Highway Truck Engine Supplement Refrigerant Condenser - Remove and Install
2013/07/11 New Engine Harness Assembly Is Now Used On Certain Applications Equipped With C9 Engines {1408}
826K Landfill Compactor Cooling System Coolant (ELC) - Change
MH3037, MH3049 and MH3059 Material Handlers Air Conditioning and Heating Air Conditioner Lines
Upper Front Suspension Mounting is Failing on Certain 773F and 775F Off-Highway Trucks{7051, 7201} Upper Front Suspension Mounting is Failing on Certain 773F and 775F Off-Highway Trucks{7051, 7201}
773E Off-Highway Truck Engine Supplement Fan - Remove
826K Landfill Compactor Cooling System Coolant Extender (ELC) - Add
330F MHPU Mobile Hydraulic Power Unit Machine System Electronic Control (Pilot System)
773E Off-Highway Truck Engine Supplement Fan - Install
826K Landfill Compactor Cooling System Coolant Level - Check
773E Off-Highway Truck Engine Supplement Radiator - Remove
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