793F Off-Highway Truck TA2 Technical Inspection: (S/N: SND1-UP; SSP1-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 Testing and Adjusting, KENR9188, "Electric Starting System".
		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

( 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 Transfer Pressure	724 kPa (105 psi)
	Fuel Rail Pressure	180000 kPa (26107 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status (1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	152 kPa (22 psi) to 359 kPa (52 psi)
	Engine Oil Pressure at High Idle	600 kPa (87 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	1960 rpm
	Torque Converter Stall Test Engine RPM	1300 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	179 kPa (52.9 inch mercury) to 242 kPa (71.5 inch mercury)

( 1 )

N = Normal, M = Monitor, A = Action

Performance Checks

Operational Checks

Table 7

Status (1)	Description	Specification	Actual	Comments
	Raise the Dump Body	19 seconds
	Rear Suspension Group Ride Height	203 ± 13 mm (8 ± 0.5 inch)
	Front Suspension Group Ride Height	254 ± 13 mm (10 ± 0.5 inch)
	Toe Out Measurement	48.2 mm (1.90 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic Fan and Steering System

ReferenceRefer to Testing & Adjusting, KENR8598, "Hydraulic Fan and Steering System" for more detail on the following test.

Piston Pump (Steering) Pressure - Test

Table 8

Status (1)	Description	Specification	Actual	Comments
	Pressure cutoff valve test	23000 ± 500 kPa (3335 ± 75 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering) Pressure - Test

Table 9

Status (1)	Description	Specification	Actual	Comments
	Steering Relief Valve Pressure Test	26000 ± 400 kPa (3770 ± 60 psi)
	Steering Relief Valve Flow Test	8 ± 2 L/min (2.1 ± 0.5 US gpm)

( 1 )

N = Normal, M = Monitor, A = Action

Solenoid Valve and Manifold (Rear Axle Fan, Lubrication, Steering) - Adjust

Table 10

Status (1)	Description	Specification	Actual	Comments
	Solenoid Valve and Manifold (Rear Axle Fan, Lubrication, Steering) - Pressure	18300 ± 520 kPa (2650 ± 75 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Accumulator

Table 11

Status (1)	Description	Specification	Actual	Comments
	Target Accumulator Charge Pressure	6550 ± 331 kPa (950 ± 48 psi)
	Target Temperature	21° C (70° F)

( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Hydraulic Fan) Pressure - Test

Table 12

Status (1)	Description	Specification	Actual	Comments
	Fan Speed (Standard Retarding, Low Idle or High Idle, Transmission in Neutral, No Retarding)	0 - 300 rpm
	Fan Speed (Standard Retarding, Low Idle, Brake Retarding On, Downhill)	650 ± 50 rpm
	Fan Speed (Standard Retarding, High Idle, Brake Retarding On, Downhill)	700 ± 25 rpm
	Fan Speed (Additional Retarding, Low Idle, or High Idle, Transmission in Neutral, No Retarding)	0 - 300 rpm
	Fan Speed (Additional Retarding, Low Idle, Brake Retarding On, Downhill)	650 ± 50 rpm
	Fan Speed (Additional Retarding, High Idle, Brake Retarding On, Downhill)	817 ± 25 rpm (1)

( 1 )	N = Normal, M = Monitor, A = Action
( 1 )	Ambient air temperature must be greater than 30° C (86° F) at sea level to achieve 817 rpm

Hydraulic System

ReferenceRefer to Testing & Adjusting, KENR8570, "793F and 793F XQ Off-Highway Truck Hydraulic System" for more detail on the following test.

Hoist Cylinder Performance - Test

Table 13

Status (1)	Description	Specification	Actual	Comments
	Cylinder Drift Test with empty dump body and hydraulic oil above 38° C (100° F)	6.40 mm (0.25 inch) in 12.4 minutes

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Hoist Dual Stage) - Test

Table 14

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Test (High Pressure) with hoist in the RAISED position, engine at High Idle, and hydraulic oil temperature at 38° C (100° F)	20370 to 21070 kPa (2955 to 3057 psi)
	Relief Valve Test (Low Pressure) with hoist in the LOWER position, engine at High Idle, and hydraulic oil temperature at 38° C (100° F)	3450 to 3800 kPa (500 to 550 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Braking System

ReferenceRefer to Testing & Adjusting, KENR8738, "793F and 793F XQ Off-Highway Truck Braking System" for more detail on the following test.

Brake Accumulator - Test

Table 15

Status (1)	Description	Specification	Actual	Comments
	Target Accumulator Charge Pressure	6895 ± 345 kPa (1000 ± 50 psi)
	Target Temperature	21° C (70° F)

( 1 )

N = Normal, M = Monitor, A = Action

Brakes System Pressure - Test

Table 16

Status (1)	Description	Specification	Actual	Comments
	Brake System Cut-In Pressure at Low Idle	14480 ± 483 kPa (2100 ± 70 psi)
	Brake System Cutout Pressure at Low Idle	20685 ± 483 kPa (3000 ± 70 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Main Relief Valve - Test

Table 17

Status (1)	Description	Specification	Actual	Comments
	Main Relief Valve Pressure at Low Idle, with accumulators at full charge	22400 ± 345 kPa (3250 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Pressure Reducing Valve (Pilot Oil) - Test

Table 18

Status (1)	Description	Specification	Actual	Comments
	Pressure Reducing Valve (Pilot Oil) at Low Idle, with accumulators at full charge, hoist control lever in the HOLD position	3790 ± 345 kPa (550 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Accumulator System Recovery - Test

Table 19

Status (1)	Description	Specification	Actual	Comments
	Transmission in PARK, Engine at Low Idle, Hoist lever in HOLD position. The lowest brake system pressure (2)	9500 kPa (1380 psi)
	The Accumulator recovery time	12 Seconds

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	The pressure fo this test must be checked through Cat Electronic Technician (ET)

Service Brakes and Retarder System Pressure - Test

Table 20

Status (1)	Description	Specification	Actual	Comments
	Service Brake Applied Standard Retarding Front and Rear Slack Adjuster	4200 to 5000 kPa (609 to 725 psi)
	Service Brake Applied Extended Life Retarding Front Slack Adjuster	3025 to 4225 kPa (438 to 612 psi)
	Service Brake Applied Extended Life Retarding Rear Slack Adjuster	4200 to 5000 kPa (609 to 725 psi)
	Manual Retarder Lever Applied Standard Retarding Front and Rear Slack Adjuster	3800 to 5400 kPa (551 to 783 psi)
	Manual Retarder Lever Applied Extended Life Retarding Front Slack Adjuster	2825 to 4425 kPa (409 to 641 psi)
	Manual Retarder Lever Applied Extended Life Retarding Rear Slack Adjuster	3800 to 5400 kPa (551 to 783 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Parking Brake Release Pressure - Test

Table 21

Status (1)	Description	Specification	Actual	Comments
	Parking Brake Release Pressure should be at the relief valve setting (2)	4600 ± 800 kPa (665 ± 116 psi)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	The pressure fo this test must be verified through Cat Electronic Technician (ET)

Parking Brake and Secondary Brake Release System Leakage - Test

Table 22

Status (1)	Description	Specification	Actual	Comments
	System Pressure with no Plugged Wheels (1)	690 kPa (100 psi) decrease in 1 minute
	Plugged Rear Wheels System Pressure Check (1)	690 kPa (100 psi) decrease in 1 minute
	Plugged Front Wheels System Pressure Check (1)	690 kPa (100 psi) decrease in 1 minute

( 1 )	N = Normal, M = Monitor, A = Action
( 1 )	If the oil pressure has not decreased in the first minute, then the leakage is not severe enough to affect the brake release system.

Brake Cooling Pressure - Test

Table 23

Status (1)	Description	Specification	Actual	Comments
	Oil temperature for the test procedure	79° C to 93° C (175° F to 200° F)
	Brake Cooling Pressure, engine at Low Idle	14 kPa (2 psi)
	Brake Cooling Pressure, engine at High Idle	172 kPa (25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Foot Brake Control (Service) Pilot Pressure - Test

Table 24

Status (1)	Description	Specification	Actual	Comments
	Foot Brake Control (Service) Pilot Pressure, accumulators fully charged, oil at operating pressure, apply service brake several times	4950 ± 150 kPa (718 ± 22 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Slack Adjuster - Test

Table 25

Status (1)	Description	Specification	Actual	Comments
	Oil Pressure for the front and rear wheels	25 to 150 kPa (3.6 to 21.7 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, KENR8393, "793F and 793F XQ Off-Highway Truck Power Train" for more detail on the following test.

Torque Converter Test

Table 26

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Oil Temperature (during tests)	> 80 °C (176 °F) < 121 °C (250 °F)
	Torque Converter Inlet Relief Pressure	High Idle 700 ± 100 kPa (100 ± 15 psi)
	Torque Converter Outlet Relief Pressure	Low idle 140 ± 70 kPa (20 ± 10 psi)
		High idle 517 ± 100 kPa (75 ± 15 psi)
	Maximum Torque Converter Stall RPM (1)	Standard Ar. 1508 RPM
		High Altitude Ar. 1692 RPM
	Transmission Charge Pressure	Low idle 2655 to 2930 kPa (385 to 425 psi)
		High idle 2895 to 3170 kPa (420 to 460 psi)
	Lockup Clutch Maximum Pressure NEUTRAL/CONVERTER DRIVE/HIGH IDLE (2)	0.0 ± 35 kPa (0.0 ± 5 psi)
	Lockup Clutch Applied Pressure	2345 ± 103 kPa (340 ± 15 psi)

( 1 )	N = Normal, M = Monitor, A = Action
( 1 )	Torque Limiting strategy reduces engine RPM.
( 2 )	Lockup Clutch maximum pressure in DIRECT DRIVE is set during the transmission calibration procedure.

Transmission Test

Table 27

Status (1)	Description	Specification	Actual	Comments
	Transmission Oil Temperature (During Tests)	80° to 121°C (176° to 250°F)
	Main Relief Pressure	Low idle: 2655 to 2930 kPa (385 to 425 psi)
		High idle: 2895 to 3170 kPa (420 to 460 psi)
	Transmission Lubrication Oil Pressure	Low idle: 20 to 48 kPa (3 to 7 psi)
		High idle: 117 to 180 kPa (17 to 26 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Clutch Pressures (Low Idle)

Table 28

Status (1)	Description	Specification	Actual	Comments
	Clutch 1	2425 ± 138 kPa (352 ± 20 psi)
	Clutch 2	2425 ± 138 kPa (352 ± 20 psi)
	Clutch 3	2470 ± 138 kPa (358 ± 20 psi)
	Clutch 4	2275 ± 138 kPa (330 ± 20 psi)
	Clutch 5	2725 ± 138 kPa (395 ± 20 psi)
	Clutch 6	2805 ± 138 kPa (407 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Air System

ReferenceRefer to Testing & Adjusting, KENR8572, "793F and 793F XQ Off-Highway Truck Air System" for more detail on the following test.

Air Compressor

Table 29

Status (1)	Description	Specification	Actual	Comments
	Compressor recovery time from 585 kPa (85 psi) to 690 kPa (100 psi)	40 seconds

( 1 )

N = Normal, M = Monitor, A = Action

Air Compressor Governor - Test

Table 30

Status (1)	Description	Specification	Actual	Comments
	Cut-In Pressure	645 kPa (95 psi)
	Cut-Out Pressure	815 ± 35 kPa (120 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

S.O.S

Reference Refer to Operation and Maintenance Manual, SEBU8406, "793F and 793F XQ Off-Highway Truck" for more detail on the following test.

Table 31

Status (1)	Description	Obtain	Comments
	Cooling System Coolant Sample (Level 1)
	Cooling System Coolant Sample (Level 2)
	Differential and Final Drive Oil Sample
	Engine Oil Sample
	Front Wheel Oil Sample
	Hydraulic System Oil Sample - Hoist and Brake System
	Hydraulic System Oil Sample - Steering and Hydraulic Fan System
	Torque Converter and Transmission Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action

MARYGAR

793F Off-Highway Truck TA2 Technical Inspection: (S/N: SND1-UP; SSP1-UP) 2012-11-30T18:57:00-08:00 Rating: 4.5 Diposkan Oleh: Unknown