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

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
	N	Low Idle	0 to 35 kPa (0 to 5 psi)		2068 kPa (300 psi)
	R	Low Idle	0 to 35 kPa (0 to 5 psi)		2068 kPa (300 psi)					2310 kPa (335 psi)(2)
	1	Low Idle	0 to 35 kPa (0 to 5 psi)			2068 kPa (300 psi)			2310 kPa (335 psi)
	1	High Idle	2137 ± 138 kPa (310 ± 20 psi)			1725 kPa (250 psi)			1930 kPa (280 psi)
	2	High Idle	2137 ± 138 kPa (310 ± 20 psi)		1725 kPa (250 psi)				1930 kPa (280 psi)
	3	High Idle	2137 ± 138 kPa (310 ± 20 psi)	1550 kPa (225 psi)					1930 kPa (280 psi)
	4	High Idle	2137 ± 138 kPa (310 ± 20 psi)		1725 kPa (250 psi)			1930 kPa (280 psi)
	5	High Idle	2137 ± 138 kPa (310 ± 20 psi)	1550 kPa (225 psi)				1930 kPa (280 psi)
	6	High Idle	2137 ± 138 kPa (310 ± 20 psi)		1725 kPa (250 psi)		1725 kPa (250 psi)
	7	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