Friday, November 30, 2012

793F Off-Highway Truck TA2 Technical Inspection: (S/N: SND1-UP; SSP1-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, 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    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 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    SpecificationActualComments    
   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    ActualComments
   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    ActualComments
   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    ActualComments
   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    SpecificationActualComments
   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    ActualComments
   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    ActualComments
   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    ActualComments
   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    ActualComments
   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    ActualComments
   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    SpecificationActualComments
   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    ActualComments
   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    ActualComments
   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    ActualComments
   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    SpecificationActualComments
   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    ActualComments
   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    ActualComments
   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    ActualComments
   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
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