773G and 775G Off-Highway Trucks TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565}
- Quarry Truck:
- 773G (S/N: JWS1-UP)
- 775G (S/N: MJS1-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.
- Click format to print.
- Save the document as an HTML format.
- Open the document with Microsoft Word.
Electrical System
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| 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, 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) |
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| 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
ReferenceRefer 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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| 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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| Status (1) | Description | Specification | Actual | Comments |
| Fuel System Pressure | Low Idle 650 ± 50 kPa (94 ± 7 psi) High Idle 705 ± 50 kPa (102 ± 7 psi) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Lubrication System
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| 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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| Status (1) | Description | Specification | Actual | Comments |
| Engine Speed at Low Idle | 700 + 30 - 10 rpm | |||
| Engine Speed at High Idle | 2050 ± 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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| Status (1) | Description | Specification | Actual | Comments |
|---|---|---|---|---|
| Raise the Dump Body | 15 seconds | |||
| Front Suspension Group measurement | 170 mm (6.7 inch) |
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| Rear Suspension Group measurement from Pin to Pin | 831.76 mm (32.75 inch) |
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| Toe Out Measurement | 58.67 mm (2.31 inch) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Hydraulic System
ReferenceRefer 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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| 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) |
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| Pressure at Front Pressure Tap for Service Brakes (Retarder in OFF Position at Low Idle) | 8140 ± 690 kPa (1180 ± 100 psi) |
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| Slack Adjuster for Service Brakes (Retarder in ON Position at Low Idle) | 4965 ± 690 kPa (720 ± 100 psi) |
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| 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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| 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) |
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| 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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| Secondary Brake pressure Test (Brakes are not applied, engine off, in the Neutral position) | 3800 kPa (550 psi) or above |
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| 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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| 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) |
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| 775G 18950 ± 520 kPa (2750 ± 75 psi) |
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| 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
ReferenceRefer 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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| 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 |
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| 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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| Status (1) | Description | Specification | Actual | Comments |
| Transmission lubrication Relief Valve pressure in the NEUTRAL position at low idle | 10 kPa (1.5 psi) minimum |
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| 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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| Status (1) | Description | Specification | Actual | Comments |
| Clutch 1 | Low Idle 2655 ± 172 kPa (385 ± 25 psi) High Idle 3100 ± 138 kPa (450 ± 20 psi) |
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| Clutch 2 | Low Idle 1720 ± 69 kPa (250 ± 10 psi) High Idle 1720 ± 69 kPa (250 ± 10 psi) |
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| Clutch 3 | Low Idle 2275 ± 69 kPa (330 ± 10 psi) High Idle 2275 ± 69 kPa (330 ± 10 psi) |
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| Clutch 4 | Low Idle 1930 ± 69 kPa (280 ± 10 psi) High Idle 1930 ± 69 kPa (280 ± 10 psi) |
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| Clutch 5 | Low Idle 2655 ± 172 kPa (385 ± 25 psi) High Idle 3100 ± 138 kPa (450 ± 20 psi) |
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| Clutch 6 | Low Idle 2655 ± 172 kPa (385 ± 25 psi) High Idle 3100 ± 138 kPa (450 ± 20 psi) |
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| Clutch 7 | Low Idle 2655 ± 172 kPa (385 ± 25 psi) High Idle 3100 ± 138 kPa (450 ± 20 psi) |
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| 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
ReferenceRefer 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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| Status (1) | Description | Specification | Actual | Comments |
| Main Relief Valve Secondary Steering pressure at high idlePark position | 26000 ± 400 kPa (3770 ± 58 psi) |
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| 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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| Status (1) | Description | Specification | Actual | Comments |
| High Pressure Cutoff Valve pressure at high idle | 21200 ± 350 kPa (3075 ± 50 psi) |
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| 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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| 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) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Caterpillar Information System:
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}
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
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
966M Tier 4, 966M Tier 4 Series XE, 972M Tier 4 and 972M Tier 4 Series XE Wheel Loaders Hood - Remove and Install