797F and 797F XQ Off-Highway Truck TA2 Technical Inspection {0372, 0374, 1000, 7000, 753T, 7565} Caterpillar


797F and 797F XQ Off-Highway Truck TA2 Technical Inspection {0372, 0374, 1000, 7000, 753T, 7565}

Usage:

797F LAJ
Off-Highway Truck/Tractor
797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)

Introduction

Inspections are the most basic form of condition monitoring. Inspections are easy to do and surprisingly effective at helping you spot equipment health issues. Proactive monitoring and analysis of equipment information will allow Dealers to intervene effectively before problems occur.

Note: Before adjusting product settings to comply with listed baseline TA2 values, consult SIS for the latest specification values.

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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)  Test for the pressure that is listed on the cap.     
  Freezing Point of Engine Coolant       
  Conditioner Test of Engine Coolant       
  Belt Tension      Refer to Operation and Maintenance Manual. 
(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

Fuel System Operational Checks for 797F (S/N: LTZ1-UP)

Table 4
Status(1)  Description  Specification  Actual  Comments 
  Fuel Transfer Pressure  650 to 900 kPa (94 to 131 psi)     
  Fuel Rail Pressure  180000 kPa (26107 psi)     
(1) N = Normal, M = Monitor, A = Action

Lubrication System

Table 5
Status(1)  Description  Specification  Actual  Comments 
  Engine Oil Pressure at Low Idle  407 kPa (59 psi)     
  Engine Oil Pressure at High Idle  627 kPa (91 psi)     
(1) N = Normal, M = Monitor, A = Action

Basic Engine

Table 6
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 7
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 8
Status(1)  Description  Specification  Actual  Comments 
  Raise the Dump Body  22 to 27 seconds     
  Lower the Dump Body  16 to 21 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  B = A - 46.0 mm (1.81 inch)     
(1) N = Normal, M = Monitor, A = Action

Steering System

Reference: Refer to Testing & Adjusting, KENR8734, "797F Off-Highway Truck Steering System" for more detail on the following test.

Piston Pump (Steering) Pressure - Test

Table 9
Status(1)  Description  Specification  Actual  Comments 
  Pressure cutoff valve test  24115 ± 1379 kPa (3498 ± 200 psi)     
(1) N = Normal, M = Monitor, A = Action

Relief Valve (Steering) Pressure - Test

Table 10
Status(1)  Description  Specification  Actual  Comments 
  Steering Relief Valve Pressure Test  27580 ± 345 kPa (4000 ± 50 psi)     
  Steering Relief Valve Flow Test  8 ± 2 L/min (2.1 ± 0.5 US gpm)     
(1) N = Normal, M = Monitor, A = Action

Steering Control Valve Pressure

Table 11
Status(1)  Description  Specification  Actual  Comments 
  Steering Relief Valve Pressure Test  28000 ± 1025 kPa (4065 ± 150 psi)     
  Steering Relief Valve Flow Test  10 L/min (2.6 US gpm)     
(1) N = Normal, M = Monitor, A = Action

Accumulator

Table 12
Status(1)  Description  Specification  Actual  Comments 
  Target Accumulator Charge Pressure  7235 ± 345 kPa (1050 ± 50 psi)     
  Target Temperature  21° C (70° F)     
(1) N = Normal, M = Monitor, A = Action

Hydraulic Fan System

Reference: Refer to Testing & Adjusting, KENR8746, "797F and 797F XQ Off-Highway Truck Hydraulic Fan System" for more detail on the following test.

Operational Checks for 797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)

Piston Pump (Hydraulic Fan) Pressure - Test

Table 13
Status(1)  Description  Specification  Actual  Comments 
  High Idle, Retarding, Downhill Haul, Low Altitude Arrangement  Fan Speed: 530-550 rpm
25000 kPa (3625 psi) 
   
  High Idle, Retarding, Downhill Haul, High Altitude Arrangement  Fan Speed: 580-600 rpm
25000 kPa (3625 psi) 
   
  High Idle, Retarding, Flat/Uphill Haul, Low Altitude Arrangement  Fan Speed: 530-550 rpm
35000 kPa (5075 psi) 
   
  High Idle, Retarding, Flat/Uphill Haul, High Altitude Arrangement  Fan Speed: 580-600 rpm
35000 kPa (5075 psi) 
   
(1) N = Normal, M = Monitor, A = Action

Hydraulic System

Reference: Refer to Testing & Adjusting, KENR8381, "797F Off-Highway Truck Hydraulic System" for more detail on the following test.

Hoist Cylinder Performance - Test

Table 14
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) - Test

Table 15
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)  24200 ± 700 kPa (3510 ± 102 psi)     
(1) N = Normal, M = Monitor, A = Action

Relief Valve (Hoist Cylinder Head End) - Test

Table 16
Status(1)  Description  Specification  Actual  Comments 
  Relief valve pressure (Low Idle)  23800 ± 500 kPa (3452 ± 73 psi)     
  Relief valve pressure (High Idle)  24200 ± 700 kPa (3510 ± 102 psi)     
(1) N = Normal, M = Monitor, A = Action

Relief Valve (Hoist Cylinder Rod End) - Test

Table 17
Status(1)  Description  Specification  Actual  Comments 
  Relief valve pressure (High Idle)  23200 ± 500 kPa (3365 ± 73 psi)     
(1) N = Normal, M = Monitor, A = Action

Gear Pump (Hoist and Brake Cooling) Flow - Test

Table 18
Status(1)  Description  Specification  Actual  Comments 
  Gear Pump Flow  690 to 6900 kPa (100 to 1001 psi)     
(1) N = Normal, M = Monitor, A = Action

Braking System

Reference: Refer to Testing & Adjusting, KENR8374, "797F and 797F XQ Off-Highway Truck Braking System" for more detail on the following test.

Brake Accumulator - Test

Table 19
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 20
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 21
Status(1)  Description  Specification  Actual  Comments 
  Main Relief Valve Pressure at Low Idle, with accumulators at full charge  23100 ± 345 kPa (3350 ± 50 psi)     
(1) N = Normal, M = Monitor, A = Action

Brake Pilot Pressure (Foot Pedal) - Test

Table 22
Status(1)  Description  Specification  Actual  Comments 
  Engine at Low Idle, with accumulators at full charge  4950 ± 150 kPa (718 ± 22 psi)     
(1) N = Normal, M = Monitor, A = Action

Brake Accumulator System Recovery - Test

Table 23
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 for this test must be checked through Cat Electronic Technician (ET)

Service Brakes and Retarder System Pressure - Test

Table 24
Status(1)  Description  Specification  Actual  Comments 
  Service Brake Applied
Front and Rear Slack Adjuster 
6205 ± 275 kPa (900 ± 40 psi)     
  Manual Retarder Lever Applied
Front and Rear Slack Adjuster 
4135 to 6480 kPa (600 to 940 psi)     
(1) N = Normal, M = Monitor, A = Action

Parking Brake Release Pressure - Test

Table 25
Status(1)  Description  Specification  Actual  Comments 
  Parking Brake Release Pressure (Retarder Lever Applied, Transmission in N)  4340 ± 480 kPa (630 ± 70 psi)     
(1) N = Normal, M = Monitor, A = Action

Pressure Reducing Valve (Pilot Oil) - Test

Table 26
Status(1)  Description  Specification  Actual  Comments 
  Pressure Reducing Valve (Pilot Oil)  3790 ± 345 kPa (550 ± 50 psi)     
(1) N = Normal, M = Monitor, A = Action

Parking Brake and Secondary Brake Release System Leakage - Test

Table 27
Status(1)  Description  Specification  Actual  Comments 
  System Pressure with no Plugged Wheels(2)  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
(2) 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 28
Status(1)  Description  Specification  Actual  Comments 
  Brake Cooling Pressure  480 ± 340 kPa (70 ± 50 psi)     
(1) N = Normal, M = Monitor, A = Action

Slack Adjuster - Test

Table 29
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

Reference: Refer to Testing & Adjusting, KENR8371, "797F and 797F XQ Off-Highway Truck Power Train" for more detail on the following test.

Torque Converter Test

Table 30
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  Low idle
145 ± 50 kPa (21 ± 7 psi) 
   
  High Idle
725 ± 105 kPa (105 ± 15 psi)
   
  Torque Converter Outlet Relief Pressure  Low idle
110 ± 50 kPa (16 ± 7 psi) 
   
  High idle
450 ± 105 kPa (65 ± 15 psi)
   
  Maximum Torque Converter Stall RPM (2)  1600 ± 65 RPM     
  Transmission Charge Pressure "R1N" and "JH5" Transmissions  Low idle
2310 ± 138 kPa (335 ± 20 psi)
High idle
2650 ± 138 kPa (385 ± 20 psi) 
Low idle:
High idle: 
 
  Lockup Clutch Maximum Pressure
NEUTRAL/CONVERTER DRIVE/HIGH IDLE(3) 
0.0 ± 35 kPa (0.0 ± 5 psi)     
(1) N = Normal, M = Monitor, A = Action
(2) Torque Limiting strategy reduces engine RPM.
(3) Lockup Clutch maximum pressure in DIRECT DRIVE is set during the transmission calibration procedure.

Transmission Test

Table 31
Status(1)  Description  Specification  Actual  Comments 
  Trans Oil Temperature (During Tests)  80° to 120°C (176° to 248°F)     
  Main Relief Pressure (Low Idle)  2310 ± 172 kPa (335 ± 25 psi) on "R1N" and "JH5" Transmission     
(1) N = Normal, M = Monitor, A = Action

Transmission Lubrication Pressures

Table 32
Status(1)  Transmission Pump and Lubrication Pressure for "R1N" and "JH5" Transmissions 
Engine Speed
Trans. Control
Transmission Pump Pressure (Main Relief)  Rear Box Lubrication Pressure  Front Box Lubrication Pressure  Comments 
Target Actual  Target  Actual  Target  Actual 
  Low Idle
Trans. in Neutral 
2310 ± 138 kPa (335 ± 20 psi)    90 ± 35 kPa (13 ± 5 psi)    70 ± 14 kPa (10 ± 2 psi)     
  Low Idle
Trans. in Reverse 
2310 ± 138 kPa (335 ± 20 psi)    90 ± 35 kPa (13 ± 5 psi)    70 ± 14 kPa (10 ± 2 psi)     
  Low Idle
Trans. in First, 
2310 ± 138 kPa (335 ± 20 psi)    90 ± 35 kPa (13 ± 5 psi)    70 ± 14 kPa (10 ± 2 psi)     
  High Idle
Trans. in First 
2650 ± 138 kPa (384 ± 20 psi)    550 ± 70 kPa (80 ± 10 psi)    455 ± 70 kPa (66 ± 10 psi)     
  High Idle
Trans. in Fourth 
2650 ± 138 kPa (384 ± 20 psi)    550 ± 70 kPa (80 ± 10 psi)    455 ± 70 kPa (66 ± 10 psi)     
  High Idle
Trans. in Sixth 
2650 ± 138 kPa (384 ± 20 psi)    575 ± 70 kPa (83 ± 10 psi)(2)    455 ± 70 kPa (66 ± 10 psi)     
(1) N = Normal, M = Monitor, A = Action
(2) Machines S/N:LAJ263-UP are equipped with an updated lubrication manifold, and will show reduced lube pressure for clutches 6 and 7. For transmissions with an updated lubrication manifold, no lube test is now required for clutches 6 and 7.

Transmission Clutch Pressures

Table 33
Status(1)  Transmission Clutch Pressures 
Gear Eng. Speed  Lockup Clutch Press.  Clutches Engaged and Pressures ± 138 kPa (± 20 psi) 
1 2 3 4 5  6  7 
  Low Idle  0 to 35 kPa (0 to 5 psi)    2068 kPa (300 psi)           
  Low Idle  0 to 35 kPa (0 to 5 psi)    2068 kPa (300 psi)          2310 kPa (335 psi)(2) 
  Low Idle  0 to 35 kPa (0 to 5 psi)      2068 kPa (300 psi)      2310 kPa (335 psi)   
  High Idle  2137 ± 138 kPa (310 ± 20 psi)      1725 kPa (250 psi)      1930 kPa (280 psi)   
  High Idle  2137 ± 138 kPa (310 ± 20 psi)    1725 kPa (250 psi)        1930 kPa (280 psi)   
  High Idle  2137 ± 138 kPa (310 ± 20 psi)  1550 kPa (225 psi)          1930 kPa (280 psi)   
  High Idle  2137 ± 138 kPa (310 ± 20 psi)    1725 kPa (250 psi)      1930 kPa (280 psi)     
  High Idle  2137 ± 138 kPa (310 ± 20 psi)  1550 kPa (225 psi)        1930 kPa (280 psi)     
  High Idle  2137 ± 138 kPa (310 ± 20 psi)    1725 kPa (250 psi)    1725 kPa (250 psi)       
  High Idle  2137 ± 138 kPa (310 ± 20 psi)  1550 kPa (225 psi)      1725 kPa (250 psi)       
(1) N = Normal, M = Monitor, A = Action
(2) "R1N" and "JH5" Transmissions

Air System

Reference: Refer to Testing & Adjusting, KENR8748, "797F Off-Highway Truck Air System" for more detail on the following test.

Air Compressor

Table 34
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 35
Status(1)  Description  Specification  Actual  Comments 
  Cut-In Pressure  655 kPa (95 psi)     
  Cut-Out Pressure  837 ± 34 kPa (120 ± 5 psi)     
(1) N = Normal, M = Monitor, A = Action

S.O.S

Reference: Refer to Operation and Maintenance Manual, SEBU8417, "797F and 797F XQ Off-Highway Truck" for more detail on the following test.

Reference: Refer to Operation and Maintenance Manual, M0070546, "797F Off-Highway Truck" for more detail on the following test.

Table 36
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

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