789C Off-Highway Truck TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565} Caterpillar

Off-Highway Truck:

789C (S/N: 2BW1-UP)

Introduction

Inspections are the most basic form of condition monitoring. The 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 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, SENR1123, "Electric Starting System - Test".
		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	-		Use 245-5829 Coolant/Battery Tester Gp .
	Conditioner Test of Engine Coolant	-		Use 8T-5296 Coolant Conditioner Test Kit .
	Belt Tension	-
	Difference between the Upper Radiator Tank Temperature and Lower Radiator Tank Temperature	5° + 5° - 5° C (41° + 41° - 41°F)
	Jacket Water Inlet Temperature from Cooling System	89° ± 3°C (192° ± 37°F)

( 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 Pressure at LOW IDLE	-
	Fuel Pressure at HIGH IDLE	467 + 200 - 144 kPa (68 + 29 - 21 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status (1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	329 + 271 - 120 kPa (48 + 39 - 17 psi)
	Engine Oil Pressure at High Idle	453 + 147 - 115 kPa (66 + 21 - 17 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Basic Engine

Table 5

Status (1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle	700 ± 10 rpm
	Engine Speed at High Idle	1937 ± 10 rpm
	Torque Converter Stall Test Engine RPM	1718 ± 65 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	205.4 + 35.4 - 27.4 N·m (151.5 + 26.1 - 20.2 lb ft)
	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)
	Cylinder # 9 Exhaust Temperature (2)
	Cylinder # 10 Exhaust Temperature (2)
	Cylinder # 11 Exhaust Temperature (2)
	Cylinder # 12 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	19 seconds
	Rear Suspension Group Ride Height	203 ± 13 mm (8.0 ± 0.50 inch)
	Front Suspension Group Ride Height	254 ± 13 mm (10 ± 0.50 inch)
	Toe Out Measurement	48.5 mm (1.91 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic System

ReferenceRefer to Testing & Adjusting, SENR1532, "Hydraulic Systems" for more detail on the following tests.

Hoist Cylinder Performance - Test

Table 8

Acceptable Cylinder Drift
Status (1)	Minutes	Oil Temperature	Cylinder Drift	Actual	Comments
	12.4	38° C (100° F)	6.40 mm (0.25 inch)
	9.6	43° C (110° F)	6.40 mm (0.25 inch)
	7.8	49° C (120° F)	6.40 mm (0.25 inch)
	6.4	54° C (130° F)	6.40 mm (0.25 inch)
	5.3	60° C (140° F)	6.40 mm (0.25 inch)
	4.4	66° C (150° F)	6.40 mm (0.25 inch)
	3.8	71° C (160° F)	6.40 mm (0.25 inch)
	3.2	77° C (170° F)	6.40 mm (0.25 inch)
	2.8	82° C (180° F)	6.40 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
	High Pressure	17225 to 17925 kPa (2500 to 2600 psi)
	Low Pressure	3450 to 3800 kPa (500 to 550 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Rear Brake Oil Cooler) - Test and Adjust

Table 10

Status (1)	Description	Specification	Actual	Comments
	Maximum Pressure	790 ± 20 kPa (115 ± 3 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Gear Pump (Hoist and Rear Brake Cooling) Efficiency - Test

Table 11

Status (1)	Description	Specification	Actual	Comments
	Maximum percent flow loss	10%

( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, SENR1523, "Power Train System" for more detail on the following test.

Relief Valve (Torque Converter Outlet) Pressure - Test and Adjust

Table 12

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure	345 to 552 kPa (50 to 80 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Torque Converter Inlet) Pressure - Test and Adjust

Table 13

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure	Less than 930 ± 35 kPa (135 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Supply Pressure - Test and Adjust

Table 14

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Supply Pressure	4690 ± 200 kPa (680 ± 29 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pilot Pressure - Test and Adjust

Table 15

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Pilot Pressure	1725 ± 70 kPa (250 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Leakage - Test

Table 16

Status (1)	Description	Specification	Actual	Comments
	Maximum flow rate	3.8 L/min (1 US gpm)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Signal Pressure - Test

Table 17

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Signal Pressure with the lockup solenoid deactivated at LOW IDLE	0
	Torque Converter Lockup Clutch Signal Pressure with the lockup clutch activated at HIGH IDLE	1725 kPa (250 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Maximum Pressure - Test

Table 18

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Maximum Pressure	2140 ± 70 kPa (310 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Primary Pressure - Test and Adjust

Table 19

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Primary Pressure	1030 ± 35 kPa (150 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Gear Pump (Transmission Charging) Pressure - Test and Adjust

Table 20

Status (1)	Description	Specification	Actual	Comments
	Gear Pump Pressure with the lockup clutch solenoid is deactivated at LOW IDLE	2515 kPa (365 psi)
	Gear Pump Pressure with the lockup clutch is deactivated at HIGH IDLE	3175 kPa (461 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Dual Stage Relief Valve Pressure - Test and Adjust

Table 21

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Pressure with the lockup clutch solenoid is deactivated at LOW IDLE	2515 kPa (365 psi)
	Relief Valve Pressure with the lockup clutch solenoid is deactivated at MEDIUM IDLE	2100 ± 105 kPa (305 ± 15 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Clutch Pressure - Test

Table 22

Measurements of the Clutch Pressure
Station (1)	"A"	"B"	"C"	"D" (2)	"E"	"F"	"G"
Low Idle (3) Pressure (4)	N/A	2760 kPa (400 psi)	N/A	N/A	N/A	2585 kPa (375 psi)	2760 kPa (400 psi)
Actual	N/A		N/A	N/A	N/A
High Idle (3) Pressure (4)	N/A	2890 kPa (419 psi) (5)	2470 kPa (358 psi)	N/A	N/A	2720 kPa (395 psi)	2805 kPa (407 psi)
Actual	N/A			N/A	N/A
1300 rpm (6) Pressure (4)	2020 kPa (293 psi)	2020 kPa (293 psi)	2020 kPa (293 psi)	N/A	2020 kPa (293 psi)	2020 kPa (293 psi)	N/A
Actual				N/A			N/A

( 1 )	Station "H" is not used.
( 2 )	Station "D" does not control a clutch. Station "D" controls the dual stage relief valve for the system pressure.
( 3 )	Torque converter drive
( 4 )	The tolerance is + 240 − 100 kPa (+ 35 − 15 psi), except when the pressure is noted otherwise.
( 5 )	The tolerance is + 225 − 225 kPa (+ 33 − 33 psi).
( 6 )	Direct drive

Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust

Table 23

Measurements of the Primary Clutch Pressure
Station (1)	"A"	"B"	"C"	"D" (2)	"E"	"F"	"G"
Low Idle Pressure (3)	525 kPa (76.1 psi)	475 kPa (68.9 psi)	480 kPa (69.6 psi)	N/A	425 kPa (61.6 psi)	450 kPa (65.3 psi)	425 kPa (61.6 psi)
Actual				N/A

( 1 )	Station "H" is not used.
( 2 )	Station "D" does not control a clutch. Station "D" controls the dual stage relief valve for the system pressure.
( 3 )	The tolerance is +50 − 35 (+7 − 5).

Table 24

Specifications and Identification of the Components of the Pressure Control Valve
Location of the Load Piston Body (1)	A	B	C	D	E	F	G
Thickness of the Load Piston Orifice	4.58 mm (.180 inch)	2.54 mm (.100 inch)	2.54 mm (.100 inch)		2.54 inch (.100 inch)	6.60 mm (0.260 inch)	6.60 mm (.260 inch)
Color of the Outer Spring of the Load Piston	Light green color	Yellow color	Light green color		Light green color	Light green color	Light green color
Color of the Inner Spring of the Load Piston	Light blue color	Light blue color	Light blue color		Orange color	Yellow color	Light green color
Size of the Decay Orifice	1.40 mm (0.055 inch)	1.57 mm (0.062 inch)	1.98 mm (0.078 inch)		1.57 mm (0.062 inch)	1.40 mm (0.055 inch)
Color of the Decay Orifice	Yellow color	Green color	Red color		Green color	Yellow color

( 1 )

The location of the load piston body is identical to the location of the station for the valve. Station "H" is not used.

Table 25

(1) Shims for the Pressure Control Valve Pressure Change per Shim
Station (1)	A	B	C	D (2)	E	F	G
Engaged Clutch	2	1	3	-	4	5	6
Thickness of Shim	Pressure Change	Pressure Change	Pressure Change	Pressure Change	Pressure Change	Pressure Change	Pressure Change
5J-2721 Shim
0.13 mm (0.005 inch)	20 kPa (2.9 psi)	17 kPa (2.4 psi)	20 kPa (2.9 psi)	12 kPa (1.7 psi)	17 kPa (2.5 psi)	19 kPa (2.7 psi)	19 kPa (2.8 psi)
6J-3993 Shim
0.25 mm (0.010 inch)	41 kPa (5.9 psi)	33 kPa (4.8 psi)	41 kPa (5.9 psi)	25 kPa (3.6 psi)	35 kPa (5.1 psi)	37 kPa (5.4 psi)	39 kPa (5.6 psi)
4M-1751 Spacer
0.41 mm (0.016 inch)	65 kPa (9.4 psi)	53 kPa (7.7 psi)	65 kPa (9.4 psi)	39 kPa (5.7 psi)	56 kPa (8.1 psi)	59 kPa (8.6 psi)	62 kPa (9.0 psi)
5J-1036 Shim
0.80 mm (0.031 inch)	125 kPa (18.2 psi)	103 kPa (15.0 psi)	125 kPa (18.2 psi)	76 kPa (11.0 psi)	109 kPa (15.8 psi)	114 kPa (16.6 psi)	120 kPa (17.4 psi)

( 1 )	Station "H" is not used.
( 2 )	Station "D" does not control a clutch. Station "D" controls the dual stage relief valve for the system pressure.

Lubrication Relief Valve (Transmission) Pressure - Test

Table 26

Status (1)	Description	Specification	Actual	Comments
	Lubrication Relief Valve Pressure at LOW IDLE	4 kPa (0.6 psi)
	Lubrication Relief Valve Pressure at HIGH IDLE	140 to 205 kPa (20 to 30 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Pilot Pressure - Test and Adjust

Table 27

Status (1)	Description	Specification	Actual	Comments
	Transmission Hydraulic Control Pilot Pressure	1755 ± 35 kPa (255 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering System

ReferenceRefer to Testing & Adjusting, SENR1526, "Steering System" for more detail on the following test.

Piston Pump (Steering) Pressure - Test and Adjust

Table 28

Status (1)	Description	Specification	Actual	Comments
	High Pressure Cutoff Valve	20000 ± 350 kPa (2900 ± 50 psi)
	Low Pressure Standby	2000 to 3600 kPa (290 to 522 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering) - Test and Adjust

Table 29

Status (1)	Description	Specification	Actual	Comments
	Backup Relief Valve Pressure	20700 ± 400 kPa (3002 ± 58 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Control Valve - Adjust

Table 30

Status (1)	Description	Specification	Actual	Comments
	Pressure Setting For the Steering Check and Relief Valve	28000 to 29000 kPa (4060 to 4205 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Accumulator - Test and Charge for 789C S/N:2BW1-528

Table 31

Status (1)	Description	Specification	Actual	Comments
	Steering Accumulator Pressure	5500 ± 350 kPa (798 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Accumulator - Test and Charge for 789C S/N:2BW529-UP

Table 32

Status (1)	Description	Specification	Actual	Comments
	Steering Accumulator Pressure	6550 ± 331 kPa (950 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Worksheets

Table 33

Status (1)	Description	Specification	Actual	Comments
	Cut-out Pressure (Accumulator Charging Valve)	18300 ± 350 kPa (2654 ± 50 psi)		Steering
	Cut-in Pressure (Accumulator Charging Valve)	16470 ± 350 kPa (2390 ± 50 psi)		Steering
	Cutoff Pressure (Pressure Compensator Valve)	20000 ± 350 kPa (2900 ± 50 psi)		Steering
	Low Pressure Standby (Pressure Compensator Valve)	2100 ± 100 kPa (305 ± 15 psi)		Steering

( 1 )

N = Normal, M = Monitor, A = Action

Braking System

ReferenceRefer to Testing & Adjusting, SENR1528, "Air System and Brakes" for more detail on the following test.

Parking Brake System Pressure - Test and Adjust

Table 34

Status (1)	Description	Specification	Actual	Comments
	Parking Brake System Pressure	4690 ± 200 kPa (680 ± 29 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Service Brake Discs - Check

Table 35

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 36

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.

Service Brakes and Retarder System Leakage - Check

Table 37

Status (1)	Description	Specification	Actual	Comments
	Delivery pressure of the Retarder Air Control Valve in the full ON position	550 kPa (80 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Service Brakes and Retarder System Pressure - Test

Table 38

Status (1)	Description		Specification	Actual	Comments
	Retarder On	Rear slack adjuster	3650 kPa (530 psi)
		Front slack adjuster	3650 kPa (530 psi)
		Rear brake master cylinder	550 kPa (80 psi)
	Retarder Off	Rear slack adjuster	4345 to 5445 kPa (630 to 790 psi)
		Front slack adjuster	4345 to 5445 kPa (630 to 790 psi)
		Rear brake master cylinder	655 to 827 kPa (95 to 120 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Slack Adjuster - Test and Adjust

Table 39

Status (1)	Description	Specification	Actual	Comments
	Pressure at Rear Wheel	65 kPa (9.4 psi)
	Pressure at Front Wheel	106 kPa (15.4 psi)
	Force to move piston	220 N (50 lb)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Cooling Pressure - Check

Table 40

Status (1)	Description	Specification	Actual	Comments
	Low Idle	14 kPa (2 psi)
	High Idle	172 kPa (25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Electric Drive Pump) - Adjust

Table 41

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure of the Electric Powered Parking Brake Release Pump	4481 kPa (650 psi) maximum
		3792 kPa (550 psi) minimum

( 1 )

N = Normal, M = Monitor, A = Action

Air System

ReferenceRefer to Testing & Adjusting, SENR1528, "Air System and Brakes" for more detail on the following test.

Air Compressor Governor - Test and Adjust

Table 42

Status (1)	Description	Specification	Actual	Comments
	Cut in pressure	655 kPa (95 psi)
	Cut out pressure	830 ± 35 kPa (120 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU7174, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Table 43

Status (1)	Description	Obtain		Comments
	Engine Oil Sample
	Cooling System Coolant Sample (Level I)
	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