777E Off-Highway Truck TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565}
17/04/2017
(M0076642-01)
SMCS - 0372, 1000, 7000, 753T, 7565 i07018066
PSP
Off-Highway Truck/Tractor
-
777E (S/N: KDP1-UP; KDZ1-UP)
Introduction 2 026 0020
13: /03/ C5EC
Inspections are the most basic form of condition monitoring. Inspections are easy to do and
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effective at helping you spot equipment health issues. Proactive monitoring and analysis of
equipment information will allow Dealers to intervene before problems occur.
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Note: Before adjusting product settings to comply with listed baseline TA2 values, consult SIS
4
for the latest specification values.
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Electrical System
Table 1
Status(1) Description Specification Actual Comments
Cables between the battery, the
starter, and the engine ground
must be the correct size. Wires
Inspect
and cables must be free of
Battery
corrosion. Wires and cables must
Cables
have cable support clamps to
prevent stress on battery
connections (terminals).
Refer to Special
Instruction, SEHS7633,
Battery Test 12.4 VDC or more
"Battery Test
Procedure".
Refer to Special
Charging Instruction, REHS0354,
18 VDC to 32 VDC
System Test "Charging System
Troubleshooting".
12 to 16 V at −23° C (−10° F) to
−7° C (19° F)
Refer to Testing and
Electric
14 to 18 V at −7° C (19° F) to 10° C Adjusting, SENR9937,
Starting
(50° F) "Electric Starting
System Test
System".
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
Refer to Operation and
Belt Tension
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
Reference: Refer to Testing & Adjusting, SENR9937, "Fuel System Pressure - Test" for more detail
on the following test.
Table 3
Status(1) Description Specification Actual Comments
Lower Fuel Pressure Configuration
Fuel pressure at cranking speed (100
75 kPa (11 psi)
to 135 rpm )
Fuel pressure at low idle (700 to 900 450 ± 50 kPa
rpm) (65 ± 7 psi)
Fuel pressure at high idle (1800 to 500 ± 50 kPa
2000 rpm) (73 ± 7 psi)
Higher Fuel Pressure Configuration
Fuel pressure at cranking speed (100
75 kPa (11 psi)
to 135 rpm)
Fuel pressure at low idle (700 to 900 650 ± 50 kPa
rpm) (94 ± 7 psi)
Fuel pressure at high idle (1800 to 705 ± 50 kPa
2000 rpm) (102 ± 7 psi)
(1) N = Normal, M = Monitor, A = Action
Lubrication System
Table 4
Status(1) Description Specification Actual Comments
Engine Oil Pressure at Low Idle 138 kPa (20 psi)
Engine Oil Pressure 352 kPa (51 psi)
(1) N = Normal, M = Monitor, A = Action
Basic Engine
Table 5
Status(1) Description Specification Actual Comments
Engine Speed at Low Idle 700 rpm
Engine Speed at High Idle 2250 rpm
Torque Converter Stall Test
Engine RPM
Caterpillar Electronic
Cylinder Cutout Test -
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
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
Rear Suspension Collapsed Pin to Pin 915 mm
Length (Approximate)(2) (36 inch)
Front Suspension Collapsed Exposed
8 mm (0.31 inch)
Chrome length (Approximate)(2)
64.26 mm
Toe Out Measurement
(2.53 inch)
(1) N = Normal, M = Monitor, A = Action
(2) Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks."
Hydraulic System
Reference: Refer to Testing & Adjusting, RENR8439, "Hydraulic System" for more detail on the
following test.
Hoist Cylinder Performance - Test
Table 8
Acceptable Cylinder Drift
Status(1) Minutes Oil Temperature Cylinder Drift Actual Comments
7.0 38° to 48°C (100° to 119°F) 6.35 mm (0.25 inch)
4.1 49° to 64°C (120° to 149°F) 6.35 mm (0.25 inch)
3.0 65° C (150° F) 6.35 mm (0.25 inch)
(1) N = Normal, M = Monitor, A = Action
Relief Valve (Hoist Dual Stage) - Test and Adjust
Table 9
Status(1) Description Specification Actual Comments
Relief Valve Test ((High Pressure)
18950 + 520 - 0 kPa
Engine at High Idle, Dump Body
(2750 + 75 - 0 psi)
Fully RAISED)
Relief Valve Test (Low Pressure)
3450 ± 350 kPa
Engine at High Idle, Hoist Control
(500 ± 51 psi)
Lever in the LOWER position)
(1) N = Normal, M = Monitor, A = Action
Relief Valve (Brake Oil Cooler) - Test and Adjust
Table 10
Status(1) Description Specification Actual Comments
Brake Cooler Relief Valve Pressure at 586 ± 14 kPa
Low Idle (85 ± 2 psi)
(1) N = Normal, M = Monitor, A = Action
Braking System
Reference: Refer to Testing & Adjusting, RENR8430, "Air System and Brakes" for more detail on
the following test.
Service Brake Discs - Check
Table 11
Table For Determining The Wear Of Friction Disc
Percentage Of Disc Wear Disc Thickness
0 percent 5.08 mm (0.200 inch)
10 percent 5.03 mm (0.198 inch)
20 percent 4.98 mm (0.196 inch)
30 percent 4.93 mm (0.194 inch)
40 percent 4.88 mm (0.192 inch)
50 percent 4.83 mm (0.190 inch)
60 percent 4.78 mm (0.188 inch)
70 percent 4.72 mm (0.186 inch)
80 percent 4.67 mm (0.184 inch)
90 percent 4.63 mm (0.182 inch)
100 percent 4.57 mm (0.180 inch)
Table 12
Table For Determining The Wear Of The Grooves In The Friction Disc(1)
Percentage Of Disc Wear Disc Groove Depth
0 percent 0.64 mm (0.025 inch)
10 percent 0.62 mm (0.024 inch)
20 percent 0.60 mm (0.024 inch)
30 percent 0.59 mm (0.023 inch)
40 percent 0.57 mm (0.022 inch)
50 percent 0.55 mm (0.022 inch)
60 percent 0.53 mm (0.021 inch)
70 percent 0.51 mm (0.020 inch)
80 percent 0.50 mm (0.020 inch)
90 percent 0.48 mm (0.019 inch)
100 percent 0.46 mm (0.018 inch)
(1) This measurement is based on three measurements per side and the measurements are taken at 25.4 mm
(1.00 inch) from the outside of the disc.
Air Compressor and Governor - Test and Adjust
Table 13
Status(1) Description Specification Actual Comments
Cut-in Pressure 758 kPa (110 psi)
Cut out Pressure 930 ± 35 kPa (135 ± 5 psi)
(1) N = Normal, M = Monitor, A = Action
Service Brakes and Retarder System Pressure - Test
Table 14
Status(1) Description Specification Actual Comments
Oil Pressure at the Rear Slack
3640 kPa (528 psi)
Adjuster (Retarder Control Lever in
maximum
ON Position at High Idle)
Oil Pressure at the Front Slack
Adjuster (if equipped) (Retarder 6509 kPa (944 psi)
Control Lever in ON Position at High maximum
Idle)
Oil Pressure to the Front Caliper
Service Brakes (Retarder Control 0 kPa (0 psi)
Lever in ON Position at High Idle)
Air Pressure at the Air/Hydraulic 550 kPa (80 psi)
Cylinder for the Rear Brakes
(Retarder Control Lever in ON
Position at High Idle)
Air Pressure at the Air/Hydraulic
Cylinder for the Front Caliper Service
0 kPa (0 psi)
Brakes (Retarder Control Lever in ON
Position at High Idle)
Air Pressure at the Air/Hydraulic
Cylinder for the Front Oil Cooled
550 kPa (80 psi)
Brakes (Retarder Control Lever in ON
Position at High Idle)
Oil Pressure at the Rear Slack
Adjuster with Service Brake applied 4323 to 5702 kPa
(Retarder Control Lever in OFF (627 to 825 psi)
Position at High Idle)
Oil Pressure at the Front Slack
Adjuster with Service Brake applied 7729 to 10195 kPa
(if equipped) (Retarder Control Lever (1120 to 1480 psi)
in OFF Position at High Idle)
Oil Pressure to the Front Caliper
Service Brakes with Service Brake
19822 kPa (2875 psi)
applied (Retarder Control Lever in
OFF Position at High Idle)
Air Pressure at the Air/Hydraulic
Cylinder for the Rear Brakes with
655 to 864 kPa
Service Brake applied (Retarder
(95 to 125 psi)
Control Lever in OFF Position at High
Idle)
Air Pressure at the Air/Hydraulic
Cylinder for the Front Brakes with
655 to 864 kPa
Service Brake applied (Retarder
(95 to 125 psi)
Control Lever in OFF Position at High
Idle)
(1) N = Normal, M = Monitor, A = Action
Slack Adjuster - Test and Adjust
Table 15
Status(1) Description Specification Actual Comments
Residual Pressure at the Rear Wheels 127 kPa (18 psi)
Force to move piston 220 N (50 lb)
(1) N = Normal, M = Monitor, A = Action
Brake Cooling Pressure - Check
Table 16
Status(1) Description Specification Actual Comments
Brake Cooling Pressure at LOW IDLE 14 kPa (2 psi)
Brake Cooling Pressure at HIGH IDLE 172 kPa (25 psi)
(1) N = Normal, M = Monitor, A = Action
Power Train System
Reference: Refer to Testing & Adjusting, RENR8303, "Power Train" for more detail on the
following test.
Relief Valve (Torque Converter Inlet) Pressure - Test and
Adjust
Table 17
Status(1) Description Specification Actual Comments
Torque Converter Inlet Pressure at 930 ± 35 kPa
High Idle (135 ± 5 psi)
(1) N = Normal, M = Monitor, A = Action
Relief Valve (Torque Converter Outlet) Pressure - Test and
Adjust
Table 18
Status(1) Description Specification Actual Comments
Torque Converter Outlet Pressure at
552 ± 70 kPa
High Idle for trucks with dry front
(80 ± 10 psi)
brakes
Torque Converter Outlet Pressure at
758 ± 70 kPa
High Idle for trucks with wet front
(110 ± 10 psi)
brakes
(1) N = Normal, M = Monitor, A = Action
Relief Valve (Pilot Control Pressure) - Test
Table 19
Status(1) Description Specification Actual Comments
Relief Valve (Pilot Control 2760 ± 350 kPa
Pressure (400 ± 50 psi)
(1) N = Normal, M = Monitor, A = Action
Transmission Lubrication Oil Pressure - Test
Table 20
Status(1) Description Specification Actual Comments
Transmission Lubrication Relief Valve
pressure in the NEUTRAL-1 position at 4.0 kPa (0.6 psi)
Low Idle rpm
Transmission Lubrication Relief Valve
110 ± 30 kPa
pressure in the NEUTRAL-1 position at
(16 ± 4 psi)
High Idle rpm
(1) N = Normal, M = Monitor, A = Action
Torque Converter Lockup Clutch Pressure - Test and Adjust
Table 21
Status(1) Description Specification Actual Comments
Torque Converter Lockup Clutch 2140 ± 70 kPa
Pressure at Low Idle (310 ± 10 psi)
(1) N = Normal, M = Monitor, A = Action
Steering System
Reference: Refer to Testing & Adjusting, RENR8436, "Steering System" for more detail on the
following test.
Relief Valve (Primary Steering Backup) - Test and Adjust
Table 22
Status(1) Description Specification Actual Comments
Backup Relief Valve 26000 ± 400 kPa
Pressure (3771 ± 58 psi)
(1) N = Normal, M = Monitor, A = Action
Piston Pump (Steering) Pressure - Test and Adjust
Table 23
Status(1) Description Specification Actual Comments
High Pressure Cut off Valve 21270 ± 350 kPa
Pressure (3100 ± 50 psi)
2510 ± 440 kPa
Low Pressure Standby
(364 ± 64 psi)
(1) N = Normal, M = Monitor, A = Action
Relief Valve (Secondary Steering Backup) - Test and Adjust
Table 24
Status(1) Description Specification Actual Comments
Secondary Steering Backup Relief 20700 ± 400 kPa
Valve Pressure (3002 ± 58 psi)
(1) N = Normal, M = Monitor, A = Action
Relief Valve (Secondary Steering Main) - Test and Adjust
Table 25
Status(1) Description Specification Actual Comments
Secondary Steering Main Relief 17225 ± 350 kPa
Valve Pressure (2498 ± 51 psi)
(1) N = Normal, M = Monitor, A = Action
Pressure Reducing Valve (Steering) - Test
Table 26
Status(1) Description Specification Actual Comments
Pressure Reducing Valve 2600 + 500 - 200 kPa
Pressure (377 + 73 - 29 psi)
(1) N = Normal, M = Monitor, A = Action
Relief Valve (Steering Cylinder) - Test
Table 27
Status(1) Description Specification Actual Comments
Steering Cylinder Relief Valve 27200 ± 690 kPa
Pressure (3945 ± 100 psi)
(1) N = Normal, M = Monitor, A = Action
S.O.S
Reference: Refer to Operation and Maintenance Manual, SEBU9388, "Maintenance Interval
Schedule" for more detail on performing S.O.S. samples.
Table 28
Status(1) Description Obtain Comments
Engine Oil Sample
Cooling System Coolant Sample (Level)
Cooling System Coolant Sample (Level II)
Hoist, Torque Converter, and Brake Tank Oil Sample
Front Wheel Oil Sample
Differential and Final Drive Oil Sample
Transmission Tank Oil Sample
Steering System Oil Sample
(1) N = Normal, M = Monitor, A = Action
PSP-0002C5EC
2026/03/29
13:00:03+08:00
i06815278
© 2026 Caterpillar Inc.