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Saturday, December 1, 2012

777G Off-Highway Truck TA2 Technical Inspection: (S/N: RDR1-UP)





Electrical System

Table 1
Status (1)   DescriptionSpecification    ActualComments    
   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 Special Instruction, REHS0354, "Charging System Troubleshooting".
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    SpecificationActualComments    
   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    
752 ± 248 kPa (109 ± 36 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Lubrication System

Table 4
Status (1)    Description    Specification    Actual    Comments    
   Engine Oil Pressure at Low Idle             
   Engine Oil Pressure at High Idle             
( 1 )N = Normal, M = Monitor, A = Action


Basic Engine

Table 5
Status (1)    Description    SpecificationActualComments    
   Engine Speed at Low Idle    700 ± 10 rpm          
   Engine Speed at High Idle    2000 ± 10 rpm          
   Torque Converter Stall Test Engine RPM    1200 ± 10 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    68.1 ± 10 IN_HG          
   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    ActualComments
   Raise the Dump Body    15 seconds          
   Front Suspension Group measurement (exposed rod)   
170 mm (6.7 inch)   		      
   Rear Suspension Group measurement from Pin to Pin    
780 mm (30.7 inch)    		      
   Rear Suspension Group measurement fully extended    
830.6 mm (32.7 inch)    		      
   Toe Out Measurement    
64.3 mm (2.53 inch)    		      
( 1 )N = Normal, M = Monitor, A = Action


Hydraulic System

ReferenceRefer to Testing & Adjusting, KENR9933, "Hydraulic and Braking System" for more detail on the following test.

Service Brakes and Retarder System Pressure - Test

Service Brakes and Retarder System Pressure - Test
Table 8
Status (1)   Description    Specification    ActualComments
   Pressure at the Rear Slack Adjuster with Service Brakes Released (Retarder in ON Position at Low Idle)    
4274.75 kPa (620 psi) to
5653.7 kPa (820 psi)    		      
   Pressure at the Front Slack Adjuster with Service Brakes Released (Retarder in ON Position at Low Idle)    
4274.75 kPa (620 psi) to
5653.7 kPa (820 psi)    		      
   Pressure for Front and Rear Slack Adjuster (With Retarder to the OFF Position)    
138 kPa (20 psi)    		      
   Pressure at the Rear Slack Adjuster with Service Brakes Applied (at Low Idle)    
6067.4 ± 703.3 kPa (880 ± 102 psi)    		      
   Pressure at the Rear Slack Adjuster with Service Brakes Applied (at Low Idle)    
6067.4 ± 703.3 kPa (880 ± 102 psi)    		      
   Pressure for Front and Rear Slack Adjuster (with Service Brakes Released)    
138 kPa (20 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Secondary Brake System Pressure Test

Table 9
Status (1)   Description    Specification    ActualComments
   Secondary Brake pressure Test (Service Brakes applied, at Low Idle, in the Neutral position)    
5033 ± 690 kPa (730 ± 100 psi)    		      
   Secondary Brake pressure Test (Secondary Brakes fully applied at Low Idle, in the Neutral position)    less than
140 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
140 kPa (20 psi)  		      
( 1 )N = Normal, M = Monitor, A = Action


Relief Valve (Hoist Raise, Hoist Lower) - Test and Adjust

Table 10
Status (1)   Description    Specification    ActualComments
   Relief Valve Test ((High Pressure) Engine at high idle, Dump bed fully RAISED)    
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)    		      
( 1 )N = Normal, M = Monitor, A = Action


Relief Valve (Brake Oil Cooler) - Test and Adjust

Table 11
Status (1)   Description    SpecificationActualComments
   Brake cooler relief valve at low idle, hoist control lever in the Float position, while body is in the SNUB position    
1725 kPa (250 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Power Train System

ReferenceRefer to Testing & Adjusting, KENR9927, "Power Train System" for more detail on the following test.

Relief Valve (Torque Converter Inlet) - Test and Adjust

Table 12
Status (1)    Description    Specification   Actual    Comments
   Torque Converter Inlet Pressure at Stall rpm    
380 kPa (55 psi) to
520 kPa (75 psi)    		      
   Torque Converter Oil Temperature During Test    
71° C (160° F) to
94° C (201° F)   		      
( 1 )N = Normal, M = Monitor, A = Action


Gear Pump (Torque Converter Charging) Pressure - Test and Adjust

Table 13
Status (1)   Description    SpecificationActualComments    
   Torque Converter Inlet Relief Valve Pressure (Lockup Clutch Solenoid Deactivated)    Minimum of
103 kPa (15 psi)    		   Engine at low idle rpm, parking brakes engaged, transmission in the NEUTRAL position    
   Torque Converter Inlet Relief Valve Pressure (Lockup Clutch Solenoid Deactivated)    Maximum of
930 kPa (135 psi)    		   Engine at high idle rpm, transmission in the NEUTRAL position    
( 1 )N = Normal, M = Monitor, A = Action


Gear Pump (Transmission Charging) Pressure - Test and Adjust

Table 14
Status (1)   Description    SpecificationActualComments    
   Main Relief Valve Pressure (Lockup Clutch Solenoid Deactivated)    Minimum of
2515 kPa (365 psi)    		   Engine at low idle rpm, parking brakes engaged, transmission in the NEUTRAL position    
   Main Relief Valve Pressure (Lockup Clutch Deactivated)   Maximum of
3175 kPa (461 psi)    		   Engine at high idle rpm, transmission in the NEUTRAL-1 position    
( 1 )N = Normal, M = Monitor, A = Action


Transmission Lubrication Oil Pressure - Test

Table 15
Status (1)   Description    SpecificationActualComments
   Transmission lubrication Relief Valve pressure in the NEUTRAL position at Low Idle rpm    
7 kPa (1 psi) to
55 kPa (8 psi)    		      
   Transmission lubrication Relief Valve pressure in the NEUTRAL position at High Idle rpm    
170 kPa (25 psi) to
275 kPa (40 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Transmission Pressures - Test and Adjust (Low Idle)

Table 16
Status (1)    Description    Specification    Actual    Comments
   Clutch 1    
3103 ± 35 kPa (450 ± 5 psi)    		      
   Clutch 2    
1724 ± 35 kPa (250 ± 5 psi)    		      
   Clutch 3    
2275 ± 35 kPa (330 ± 5 psi)    		      
   Clutch 4    
1931 ± 35 kPa (280 ± 5 psi)    		      
   Clutch 5    
3103 ± 35 kPa (450 ± 5 psi)    		      
   Clutch 6    
3103 ± 35 kPa (450 ± 5 psi)    		      
   Clutch 7    
3103 ± 35 kPa (450 ± 5 psi)    		      
   Pressure of the Transmission System    
3103 ± 35 kPa (450 ± 5 psi)    		      
   Transmission Lubrication System    
21 kPa (3 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Transmission Pressures - Test and Adjust (High Idle)

Table 17
Status (1)    Description    Specification    Actual    Comments    
   Clutch 1    
3241 kPa (470 psi)    		      
   Clutch 2    
1724 kPa (250 psi)    		      
   Clutch 3    
2413 kPa (350 psi)    		      
   Clutch 4    
1965 kPa (285 psi)    		      
   Clutch 5    
3241 kPa (470 psi)    		      
   Clutch 6    
3241 kPa (470 psi)    		      
   Clutch 7    
3241 kPa (470 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Steering System

ReferenceRefer to Testing & Adjusting, KENR9935, "Steering System" for more detail on the following test.

Control Manifold (Steering) - Test and Adjust

Table 18
Status (1)   Description    Specification    ActualComments
   Main Relief Valve Secondary Steering (engine stopped)    
260 ± 4 bar (3770 ± 58 psi)    		      
   Backup Relief Valve (engine stopped)    
20700 ± 400 kPa (3002 ± 58 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Piston Pump (Steering, Fan) - Test and Adjust

Table 19
Status (1)   Description    Specification    ActualComments
   High Pressure Cutoff Valve pressure at high idle and zero flow    
20850 kPa (3024 psi) to
21550 kPa (3125 psi)    		      
   Flow Compensator Valve pressure at high idle    
2000 kPa (290 psi) to
3600 kPa (522 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Hydraulic Fan Drive System

ReferenceRefer to Testing & Adjusting, KENR9935, "Steering System" for more detail on the following test.

Piston Pump (Steering, Fan) - Test and Adjust

Table 20
Status (1)   Description    Specification    ActualComments
   High Pressure Cutoff Valve pressure at high idle and zero flow    
20850 kPa (3024 psi) to
21550 kPa (3125 psi)    		      
   Flow Compensator Valve pressure at high idle    
2000 kPa (290 psi) to
3600 kPa (522 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU8095 for more detail on the following test.
Table 21
Status (1)    Description    Obtain    Comments    
   Engine Coolant Sample (Level II)    Initial 500 Hours       
   Engine Coolant Sample (Level I)    Every 500 Service Hours       
   Differential and Final Drive Oil Sample    Every 500 Service Hours       
   Engine Oil Sample    Every 500 Service Hours       
   Front Wheel Oil Sample    Every 500 Service Hours       
   Hoist and Brake Tank Oil Sample    Every 500 Service Hours       
   Steering System Oil Sample    Every 500 Service Hours       
   Torque Converter and Transmission Oil Sample    Every 500 Service Hours       
   Engine Coolant Sample (Level II)    Every Year       
( 1 )N = Normal, M = Monitor, A = Action


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