160H Motor Grader TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565} Caterpillar

Motor Grader:

160H (S/N: XZK1-UP; 2FM1-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	28 ± 1 V		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, SENR5594, "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	Auto-Tension
	Difference between the Upper Radiator Tank Temperature and Lower Radiator Tank Temperature	6° + 5° - 5° C (43° + 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 HIGH IDLE	288 + 110 - 90 kPa (42 + 16 - 13 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status (1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at LOW IDLE	170 + 430 - 60 kPa (25 + 62 - 9 psi)
	Engine Oil Pressure at HIGH IDLE	340 + 260 - 140 kPa (49 + 38 - 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Basic Engine

Table 5

Status (1)	Description	Specification	Actual	Comments
	Engine Speed at LOW IDLE	800 ± 10 RPM
	Engine Speed at HIGH IDLE	2210 ± 60 RPM
	Cylinder Cutout Test	-
	Engine Crankcase Blowby Pressure	-

( 1 )

N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

Table 6

Status (1)	Description	Specification	Actual	Comments
	Boost Pressure Test	91.5 ± 13.8 kPa (13.3 ± 2.0 psi)
	Cylinder # 1 Exhaust Temperature (2)	-
	Cylinder # 2 Exhaust Temperature (2)	-
	Cylinder # 3 Exhaust Temperature (2)	-
	Cylinder # 4 Exhaust Temperature (2)	-
	Cylinder # 5 Exhaust Temperature (2)	-
	Cylinder # 6 Exhaust Temperature (2)	-

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Compare the exhaust temperature variance at each exhaust port.

Performance Checks

Brake Performance Checks

ReferenceRefer to Operation and Maintenance Manual, SEBU7056, "Braking System - Test" for more detail on the following test.

Table 7

Status (1)	Description	Perform	Comments
	Service Brake Test
	Parking Brake Test

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic Performance Checks

ReferenceRefer to Testing and Adjusting, SENR8518, "Hydraulic and Steering System " for more detail on the following tests.

Cylinder Cycle Time - Check

Table 8

Status (1)	Description	Specification	Actual	Comments
	Blade Lift - Rod In (2)	2.8 ± 0.4
	Blade Lift - Rod Out (2)	2.5 ± 0.4
	Centershift - Rod In (2)	6.4 ± 1.1
	Centershift - Rod Out (2)	6.2 ± 0.9
	Wheel Lean - Rod In (2)	2.0 ± 0.3
	Wheel Lean - Rod Out (2)	2.0 ± 0.3
	Blade Tip - Rod In (2)	2.6 ± 0.3
	Blade Tip - Rod Out (2)	2.6 ± 0.4
	Side Shift - Rod In (2)	9.0 ± 1.3
	Side Shift - Rod Out (2)	9.1 ± 1.3
	Scarifier - Rod In (if equipped) (2)	3.0 ± 0.4
	Scarifier - Rod Out (if equipped) (2)	2.0 ± 0.3
	Ripper (If Equipped) - Rod In (2)	5.4 ± 1.5
	Ripper (If Equipped) - Rod Out (2)	4.1 ± 0.6
	Articulation - Rod In (3) (4)	3.9 ± 0.9
	Articulation - Rod Out (3)	3.9 ± 0.9
	Blade Circle - 1/4 rotation	12.2 ± 1.5
	Steering Wheel - Number of Turns	6 to 7

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Cycle times are for a "running distance" of 305 mm (12 inch).
( 4 )	When you check the cycle times for these cylinders, operate the machine at high idle and place the transmission control (lever) in the FIRST SPEED position. The differential must be unlocked.

Hydraulic and Steering System

ReferenceRefer to Testing and Adjusting, SENR8518, "Hydraulic and Steering System", and Testing and Adjusting, SENR9186, "Hydraulic and Steering System" for more detail on the following test.

Pump Control Valve (Hydraulic, Steering) - Test and Adjust

Hydraulic Pump Low Standby Pressure Adjustment for 160H S/N:2FM1-399

Table 9

Status (1)	Description	Specification	Actual	Comments
	Low Pressure Standby at HIGH IDLE	3300 ± 700 kPa (480 ± 100 psi)
	True Low Pressure Standby at HIGH IDLE	3100 ± 895 kPa (450 ± 130 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Low Standby Pressure Adjustment for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 10

Status (1)	Description	Specification	Actual	Comments
	Low Pressure Standby at HIGH IDLE	3300 ± 689 kPa (480 ± 100 psi)
	True Low Pressure Standby at HIGH IDLE	2100 ± 150 kPa (305 ± 22 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Flow Compensator (Margin Pressure) Adjustment for 160H S/N:2FM1-399

Table 11

Status (1)	Description	Specification	Actual	Comments
	Flow Compensator (Margin Pressure) at HIGH IDLE	2100 ± 100 kPa (305 ± 15 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Adjustment for Flow Compensator (Margin Pressure) for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 12

Status (1)	Description	Specification	Actual	Comments
	Flow Compensator (Margin Pressure) at HIGH IDLE	2100 ± 150 kPa (305 ± 22 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic System Pressure Adjustments for 160H S/N:2FM1-399

Table 13

Status (1)	Description	Specification	Actual	Comments
	Implement Cylinder Stall Pressure at HIGH IDLE	24150 ± 350 kPa (3500 ± 70 psi)
	Implement Relief Valve Pressure at HIGH IDLE	27600 ± 400 kPa (3900 ± 60 psi)
		25500 ± 350 kPa (3700 ± 70 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Adjustment for Hydraulic System Pressure for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 14

Status (1)	Description	Specification	Actual	Comments
	Implement Cylinder Stall Pressure at HIGH IDLE	24132 ± 1034 kPa (3500 ± 150 psi)
	Implement Relief Valve Pressure at HIGH IDLE	27600 ± 400 kPa (3900 ± 60 psi)
		25500 ± 350 kPa (3700 ± 70 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Signal Network Check for 160H S/N:2FM1-399

Table 15

Status (1)	Description	Specification	Actual	Comments
	Signal Network Pressure at LOW IDLE	3300 ± 700 kPa (480 ± 100 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Adjustment for Signal Network for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 16

Status (1)	Description	Specification	Actual	Comments
	Signal Network Pressure at HIGH IDLE	3300 ± 689 kPa (480 ± 100 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Implement) - Test and Adjust

Table 17

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Pressure	27600 ± 400 kPa (3900 ± 60 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Disc Pack Preload for Circle Drive - Adjust for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 18

Status (1)	Description	Specification	Actual	Comments
	Spring Deflection	2.30 ± 0.25 mm (0.091 ± 0.010 inch)
	Bearing Preload	0.00 to 0.13 mm (0.000 to 0.005 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Wheel Slip - Check

Table 19

Status (1)	Description	Specification	Actual	Comments
	Steering Wheel Revolutions from Stop to Stop	6.5 turns
	Maximum Steering Pressure	19300 ± 690 kPa (2800 ± 100 psi) (2)
		18616 ± 689 kPa (2700 ± 100 psi) (3)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	for 160H S/N:2FM1-399
( 3 )	for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Accumulator (Steering) - Test and Charge for 160H S/N:2FM1-399

Table 20

Status (1)	Description	Specification	Actual	Comments
	Accumulator Nitrogen Precharge	6900 kPa (1000 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Accumulator (Steering) - Test and Charge for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 21

Status (1)	Description	Specification	Actual	Comments
	Charging Pressure for the Accumulator	6890 ± 345 kPa (1000 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering) - Test and Adjust for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 22

Status (1)	Description	Specification	Actual	Comments
	Relief Valve (Steering) - Test and Adjust	22100 ± 200 kPa (3205 ± 29 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Air and Brake System

ReferenceRefer to Testing and Adjusting, RENR1417, "Air System and Brakes" and Testing and Adjusting, SENR8670, "Air System and Brakes" for more detail on the following test.

Air Pressure Gauge - Test

Table 23

Status (1)	Description	Specification	Actual	Comments
	Pressure difference between Air Pressure Gauge and Test Pressure Gauge for Right or Left Tank gauge	35 kPa (5 psi) Maximum

( 1 )

N = Normal, M = Monitor, A = Action

Air Compressor Governor - Test and Adjust

Table 24

Status (1)	Description	Specification	Actual	Comments
	Cut IN, Pressure	793 kPa (115 psi) (2)
		790 ± 70 kPa (115 ± 10 psi) (3)
	Cut OUT, Pressure	965 ± 34 kPa (140 ± 5 psi)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	for 160H S/N:2FM1-399
( 3 )	for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Pressure Switch (Low Brake Air) - Test for 160H S/N:2FM1-399

Table 25

Status (1)	Description	Specification	Actual	Comments
	Cut IN, Pressure	530 ± 40 kPa (77 ± 6 psi) Approximately
	Cut OUT, Pressure	Above 640 kPa (93 psi) Approximately
	Low Brake Air Pressure Alarm Test	530 ± 40 kPa (77 ± 6 psi)
	Low Brake Air Pressure - Indicator	530 ± 40 kPa (77 ± 6 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Pressure Switch (Low Brake Air) - Test for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 26

Status (1)	Description	Specification	Actual	Comments
	Cut IN, Pressure	530 kPa (77 psi) Approximately
	Cut OUT, Pressure	640 kPa (93 psi) Approximately
	Low Brake Air Pressure Alarm Test	530 kPa (77 psi) Minimum
	Low Brake Air Pressure - Indicator	530 kPa (77 psi) Minimum

( 1 )

N = Normal, M = Monitor, A = Action

Pressure Switch (Brake Air) (Stop Lamp) - Test

Table 27

Status (1)	Description	Specification	Actual	Comments
	Stop Lamp Brake Air Pressure Switch Test	45 kPa (7 psi) Approximately

( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing and Adjusting, SENR9159, "Power Train", and Testing and Adjusting, SENR8503, "Power Train" for more detail on the following test.

Transmission Charging Pump Pressure - Test and Adjust for 160H S/N:2FM1-399

Table 28

Status (1)	Description	Specification	Actual	Comments
	Transmission Charging Pump Pressure at LOW IDLE	2750 kPa (400 psi) (2)
	Transmission Charging Pump Pressure at HIGH IDLE	3300 kPa (480 psi) (2)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Neutral position

Transmission Charging Pump Pressure - Test and Adjust for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 29

Status (1)	Description	Specification	Actual	Comments
	Transmission Charging Pump Pressure at LOW IDLE	2690 kPa (390 psi) (2)
	Transmission Charging Pump Pressure at HIGH IDLE	3240 kPa (470 psi) (2)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Neutral position

Transmission Lubrication Oil Pressure - Test for 160H S/N:2FM1-399

Table 30

Status (1)	Description	Specification	Actual	Comments
	Transmission Lubrication Oil Pressure at LOW IDLE in NEUTRAL position	80 ± 30 kPa (12 ± 4 psi)
	Transmission Lubrication Oil Pressure at HIGH IDLE in NEUTRAL position	558 ± 55 kPa (80 ± 8 psi)
	Transmission Lubrication Oil Pressure at LOW IDLE in FIRST GEAR FORWARD position	Minimum 7 kPa (1 psi)
	Transmission Lubrication Oil Pressure at HIGH IDLE in FIRST GEAR FORWARD position	241 ± 27 kPa (35 ± 4 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Lubrication Oil Pressure - Test for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 31

Status (1)	Description	Specification	Actual	Comments
	Transmission Lubrication Oil Pressure at LOW IDLE in NEUTRAL position	28 kPa (4 psi)
	Transmission Lubrication Oil Pressure at HIGH IDLE in NEUTRAL position	345 kPa (50 psi)
	Transmission Lubrication Oil Pressure at LOW IDLE in FIRST GEAR FORWARD position	7 kPa (1 psi)
	Transmission Lubrication Oil Pressure at HIGH IDLE in FIRST GEAR FORWARD position	207 kPa (30 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Pressures - Test for 160H S/N:2FM1-399

Table 32

Status (1)	Description	Specification	Actual	Comments
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 1 (First Gear, Forward)	2180 ± 95 kPa (316 ± 14 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 2 (Second Gear, Forward)	2350 ± 95 kPa (341 ± 14 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 3 (First Gear, Reverse)	2255 ± 110 kPa (327 ± 16 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 4 (Second Gear, Forward)	1965 ± 110 kPa (285 ± 16 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 5 (Neural)	2790 ± 85 kPa (405 ± 12 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 6 (First Gear, Forward or Reverse)	2670 ± 90 kPa (387 ± 13 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 7 (First Gear, Forward or Reverse) or (Second, Forward)	1540 ± 85 kPa (223 ± 12 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 8 (Neutral)	2670 ± 95 kPa (387 ± 14 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Pressures - Test for 160H S/N:XZK1-UP and ; S/N:2FM400-UP

Table 33

Status (1)	Description	Specification	Actual	Comments
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 1 (First Gear, Forward)	2080 to 2275 kPa (302 to 330 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 2 (Second Gear, Forward)	2255 to 2445 kPa (327 to 355 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 3 (First Gear, Reverse)	2145 to 2365 kPa (311 to 343 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 4 (Second Gear, Forward)	1855 to 2075 kPa (269 to 301 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 5 (Neural)	2710 to 2875 kPa (393 to 417 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 6 (First Gear, Forward or Reverse)	2580 to 2760 kPa (374 to 400 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 7 (First Gear, Forward or Reverse) or (Second, Forward)	2525 to 2815 kPa (366 to 408 psi)
	Transmission Clutch Pressure with Differential Lock OFF at Clutch 8 (Neutral)	2570 to 2765 kPa (373 to 401 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Differential Lock Pressure - Check

Table 34

Status (1)	Description	Specification	Actual	Comments
	Differential Lock Pressure (2)	2620 kPa (380 psi) minimum

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Remove the differential drive shaft. Operate the machine in FIRST GEAR FORWARD at HIGH IDLE. Engage the differential lock valve.

Clutch Control - Test

Table 35

Status (1)	Description	Specification	Actual	Comments
	Clutch Control Pressure (2)	2125 kPa (308 psi) minimum

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Move the transmission control lever to FIRST GEAR FORWARD position and operate at half throttle. Depress clutch pedal. The transmission should be turning.

S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU7056, "Maintenance Interval Schedule" for more detail on the following test.

Table 36

Status (1)	Description	Obtain	Comments
	Engine Coolant Sample (Level 1)
	Engine Coolant Sample (Level 2)
	Engine Oil Sample
	Hydraulic Oil Sample
	Transmission/Differential Oil Sample
	Tandem Drive Oil Sample
	Wheel Bearing Oil Sample (Front)

( 1 )

N = Normal, M = Monitor, A = Action