Friday, November 30, 2012

770G and 772G Off-Highway Trucks TA2 Technical Inspection: 770G (S/N: ECM1-UP) 772G (S/N: LTS1-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 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)
( 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    -          
( 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    
717 ± 241 kPa (104 ± 35 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Lubrication System

Table 4
Status (1)    Description    SpecificationActualComments
   Engine Oil Pressure at Low Idle    -          
   Engine Oil Pressure at Full Load Speed (1800 rpm)    -          
( 1 )N = Normal, M = Monitor, A = Action


Basic Engine

Table 5
Status (1)    Description    SpecificationActualComments    
   Engine Speed at Low Idle    650 ± 20 rpm          
   Engine Speed at High Idle    2200 ± 10 rpm          
   Torque Converter Stall Test Engine RPM    1300 ± 10 rpm          
   Cylinder Cutout Test    -       Caterpillar Electronic Technician    
   Engine Crankcase Pressure (Blowby)    -          
( 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    45.3 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

ReferenceRefer to Testing & Adjusting, UENR1122 for more detail on the following checks.

Operational Checks

Table 7
Status (1)    Description    Specification    ActualComments
   Raise the Dump Body    18 seconds          
   Front Suspension Group measurement   
170 mm (6.7 inch)   		      
   Rear Suspension Group measurement from Pin to Pin    
831.76 mm (32.75 inch)    		      
   Toe Out Measurement    
50.80 mm (2.00 inch)    		      
( 1 )N = Normal, M = Monitor, A = Action


Hydraulic System

ReferenceRefer to Testing & Adjusting, UENR1122, "Hydraulic and Braking System" for more detail on the following test.

Service Brakes and Retarder System Pressure - Test

Table 8
Status (1)    Description    Specification    ActualComments
   Pressure at Slack Adjuster for Service Brakes (Retarder in OFF Position at Low Idle)    
6065 ± 345 kPa (880 ± 50 psi)    		      
   Pressure at Front Pressure Tap for Service Brakes (Retarder in OFF Position at Low Idle)  
7000 ± 690 kPa (1015 ± 100 psi)    		      
   Slack Adjuster for Service Brakes (Retarder in ON Position at Low Idle)    
5000 ± 690 kPa (725 ± 100 psi)    		      
   Pressure at Front Pressure Tap for Service Brakes (Retarder in ON Position at Low Idle)    
0 kPa (0 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Secondary Brake System Pressure Test

Table 9
Status (1)    Description    Specification    ActualComments
   Secondary Brake pressure Test (Brakes are not 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 +1000 - 500 kPa (2750 +145 -73 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, UENR1122, "Power Train System" for more detail on the following test.

Torque Converter Lockup Clutch Supply Pressure - Test and Adjust

Table 12
Status (1)   Description    SpecificationActualComments
   Modulating valve for the torque converter lockup clutch test (engine running at 1700 rpm, in the NEUTRAL position with the parking brake engaged)   
2068 ± 69 kPa (300 ± 10 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


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

Table 13
Status (1)   Description    Specification    ActualComments
   Main Relief Valve Pressure at high idle in the NEUTRAL Position and Parking Brakes are Engaged. The lockup clutch is deactivated.    
3240 ± 69 kPa (470 ± 10 psi) maximum    		      
   Main Relief Valve Pressure at low idle in the NEUTRAL Position and Parking Brakes are Engaged. The lockup clutch is deactivated.    
2515 kPa (365 psi) minimum    		      
( 1 )N = Normal, M = Monitor, A = Action


Transmission Lubrication Oil Pressure - Test

Table 14
Status (1)    Description    Specification    ActualComments
   Transmission lubrication Relief Valve pressure in the NEUTRAL position at 700 rpm    
20.5 ± 14 kPa (3 ± 2 psi)    		      
   Transmission lubrication Relief Valve pressure in the NEUTRAL position at 2200 rpm    
172 ± 34 kPa (25 ± 5 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Transmission Pressures - Test and Adjust

Table 15
Status (1)    Description    Specification    Actual    Comments
   Clutch 1    
3100 ± 35 kPa (450 ± 5 psi)    		      
   Clutch 2    
1725 ± 35 kPa (250 ± 5 psi)    		      
   Clutch 3    
2410 ± 35 kPa (350 ± 5 psi)    		      
   Clutch 4    
1930 ± 35 kPa (280 ± 5 psi)    		      
   Clutch 5    
3100 ± 35 kPa (450 ± 5 psi)    		      
   Clutch 6    
3100 ± 35 kPa (450 ± 5 psi)    		      
   Clutch 7    
3100 ± 35 kPa (450 ± 5 psi)    		      
   Transmission System Pressure at 700 rpm    
2725 ± 70 kPa (395 ± 10 psi)    		      
   Transmission System Pressure at 1817 rpm    
3100 ± 35 kPa (450 ± 5 psi)    		      

2200    		Transmission System Pressure at 2200 rpm    
3240 ± 70 kPa (470 ± 10 psi)    		      
( 1 )N = Normal, M = Monitor, A = Action


Steering System

ReferenceRefer to Testing & Adjusting, UENR1122, "Steering System" for more detail on the following test.

Control Manifold (Steering) - Test and Adjust

Table 16
Status (1)    Description    Specification    ActualComments
   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)    		      
( 1 )N = Normal, M = Monitor, A = Action


Piston Pump (Steering, Fan) - Test and Adjust

Table 17
Status (1)    Description    Specification    ActualComments
   High Pressure Cutoff Valve pressure at high idle    
20850 kPa (3024 psi)Minimum    		      
   High Pressure Cutoff Valve pressure at high idle    
21550 kPa (3126 psi)Maximum    		      
   Flow Compensator Valve pressure at high idle    
2000 kPa (290 psi)Minimum    		      
   Flow Compensator Valve pressure at high idle    
3600 kPa (522 psi)Maximum    		      
( 1 )N = Normal, M = Monitor, A = Action


Hydraulic Fan Drive System

ReferenceRefer to Testing & Adjusting, UENR1122, "Hydraulic Fan Drive System" for more detail on the following test.

Piston Pump (Steering, Fan) - Test and Adjust

Table 18
Status (1)    Description    Specification    ActualComments
   High Pressure Cutoff Valve pressure at high idle    
20850 kPa (3024 psi)Minimum    		      
   High Pressure Cutoff Valve pressure at high idle    
21550 kPa (3126 psi)Maximum    		      
   Flow Compensator Valve pressure at high idle    
2000 kPa (290 psi)Minimum    		      
   Flow Compensator Valve pressure at high idle    
3600 kPa (522 psi)Maximum    		      
( 1 )N = Normal, M = Monitor, A = Action


Generator System

ReferenceRefer to Testing & Adjusting, KENR####, "Generator System" for more detail on the following test.

Generator Set - Test

Table 19
Status (1)   Description    Specification   Actual   Comments    
   AC Voltage Across Terminals 1 and 2
Half the Rated Speed    		Enter Value          
   AC Voltage Across Terminals 1 and 3
Half the Rated Speed    		Enter Value          
( 1 )N = Normal, M = Monitor, A = Action


Winding - Test

Table 20
Status (1)    Description    Specification    Actual    Comments    
   Exciter Armature (Rotor)    Enter Value          
   Main Armature (Stator)    Enter Value          
( 1 )N = Normal, M = Monitor, A = Action


Insulation - Test

Table 21
Status (1)    Description    Specification    Actual    Comments    
   Main Armature    Enter Value          
   Exciter Field    Enter Value          
( 1 )N = Normal, M = Monitor, A = Action


S.O.S

Reference Refer to Operation and Maintenance Manual, SEBU8718, "Maintenance Interval Schedule" for more detail on the following test.
Table 22
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)          
( 1 )N = Normal, M = Monitor, A = Action


MARYGAR
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