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

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 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	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	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	Specification	Actual	Comments
	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
	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	Actual	Comments
	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

Table 8
Status ⁽¹⁾	Description	Specification	Actual	Comments
	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	Actual	Comments
	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	Actual	Comments
	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	Specification	Actual	Comments
	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	Specification	Actual	Comments
	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	Specification	Actual	Comments
	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	Specification	Actual	Comments
	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	Actual	Comments
	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	Actual	Comments
	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	Actual	Comments
	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

MARYGAR

truck

Saturday, December 1, 2012

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

Electrical System

Engine

Cooling System

Fuel System

Lubrication System

Basic Engine

Air Inlet and Exhaust System

Performance Checks

Operational Checks

Hydraulic System

Service Brakes and Retarder System Pressure - Test

Secondary Brake System Pressure Test

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

Relief Valve (Brake Oil Cooler) - Test and Adjust

Power Train System

Relief Valve (Torque Converter Inlet) - Test and Adjust

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

Gear Pump (Transmission Charging) Pressure - Test and Adjust

Transmission Lubrication Oil Pressure - Test

Transmission Pressures - Test and Adjust (Low Idle)

Transmission Pressures - Test and Adjust (High Idle)

Steering System

Control Manifold (Steering) - Test and Adjust

Piston Pump (Steering, Fan) - Test and Adjust

Hydraulic Fan Drive System

Piston Pump (Steering, Fan) - Test and Adjust

S.O.S

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