735 Articulated Truck TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565} Caterpillar

Articulated Truck:

735 (S/N: B1N1-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.

Note: Specification values are based on the following machine settings unless stated otherwise

• Engine Speed Dial "10"

• AEC OFF

• HP Mode

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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, SENR9832, "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	3 + 5 - 5 °C (37 + 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	640 ± 214 kPa (93 ± 31 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status (1)	Description	Specification	Actual	Comments
	Oil Pressure at LOW IDLE	190 + 410 - 90 kPa (28 + 59 - 13 psi)
	Oil Pressure at HIGH IDLE	390 + 210 - 115 kPa (57 + 30 - 17 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Basic Engine

Table 5

Status (1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle	2105 ± 10 rpm
	Engine Speed at High Idle	700 ± 10 rpm
	Cylinder Cutout Test			Cat® Electronic Technician (Cat ET) Service Tool
	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 Boost Pressure	133.7 to 181.1 kPa (19.4 to 26.3 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

ReferenceRefer to Testing & Adjusting, RENR5126, "Steering, Suspension, and Body Hoist Hydraulic System" for more detail on the following test.

Operational Checks

Body Hoist Cycle Time - Check

Table 7

Status (1)	Description	Specification	Actual	Comments
	Body Hoist Cycle Time - Raise	11 seconds maximum
	Body Hoist Cycle Time - Lower	7 seconds maximum

( 1 )

N = Normal, M = Monitor, A = Action

Steering Performance Checks

Table 8

Status (1)	Description	Specification	Actual	Comments
	Steering Time - Check
	Left Steering Time (High Idle)	4.6 seconds (2)
		3.0 seconds (3)
	Right Steering Time (High Idle)	4.6 seconds (2)
		3.0 seconds (3)
	Electric Drive Pump Test (Secondary Steering)
	Left Steering	13800 ± 690 kPa (2000 ± 100 psi)
	Right Steering	13800 ± 690 kPa (2000 ± 100 psi)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Maximum when the steering wheel is rotated at 60 rpm.
( 3 )	Maximum when the steering wheel is rotated at 90 rpm.
( 2 )	Maximum when the steering wheel is rotated at 60 rpm.
( 3 )	Maximum when the steering wheel is rotated at 90 rpm.

Machine Hydraulic Systems

ReferenceRefer to Testing & Adjusting, RENR5126, "Steering, Suspension, and Body Hoist Hydraulic System" for more detail on the following test.

Hoist & Body and Ejector Hydraulic System

Relief Valve (Hoist Raise, Hoist Lower) - Test and Adjust

Table 9

Status (1)	Description	Specification	Actual	Comments
	Hoist Relief Pressure - Raise	22500 ± 350 kPa (3265 ± 50 psi)
	Hoist Relief Pressure - Lower	6900 ± 150 kPa (1000 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Hoist Pilot Pressure - Test and Adjust

Table 10

Status (1)	Description	Specification	Actual	Comments
	Hoist Pilot Pressure	4825 ± 100 kPa (700 ± 15 psi) (2)
		3250 ± 350 kPa (500 ± 50 psi) (3)

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	for 735 S/N:B1N1-1197
( 3 )	for 735 S/N:B1N1198-UP

Suspension System

Suspension Cylinder (Front) - Purge and Charge

Table 11

Status (1)	Description	Specification	Actual	Comments
	Left Suspension Cylinder Height	75 ± 10 mm (3 ± 0.4 inch)
	Right Suspension Cylinder Height	75 ± 10 mm (3 ± 0.4 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Steering System

Steering System Pressure - Test

Table 12

Status (1)	Description	Specification	Actual	Comments
	Steering System Pressure (Maximum Pressure)	22000 ± 350 kPa (3190 ± 50 psi)
	Steering System Pressure (Margin Pressure)	1600 ± 140 kPa (232 ± 20 psi)
	Steering System Pressure (Standby Pressure)	4200 ± 1000 kPa (609 ± 145 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Fan Drive Pump Pressure and Fan Drive Motor Speed - Test

Table 13

Status (1)	Description	Specification	Actual	Comments
	Maximum Fan Speed (High Idle)	1800 ± 100 rpm		Set engine speed to 1700 rpm.
	Minimum Fan Speed (Low Idle)	700 ± 100 rpm

( 1 )

N = Normal, M = Monitor, A = Action

Fan Drive System Pressure (ATAAC) - Test and Adjust

Table 14

Status (1)	Description	Specification	Actual	Comments
	ATAAC Fan Pressure	18500 ± 300 kPa (2680 ± 45 psi)		If the machines not equipped with European noise suppression the pressure should be 18540 ± 340 kPa (2690 ± 50 psi)
	ATAAC Fan Speed	2300 ± 100 rpm

( 1 )

N = Normal, M = Monitor, A = Action

Braking System

ReferenceRefer to Testing & Adjusting, RENR5129, "Braking System" for more detail on the following test.

Pressure for Piston Pump (Brake) - Test

Table 15

Status (1)	Description	Specification	Actual	Comments
	Brake Piston Pump Pressure Test	21000 ± 350 kPa (3050 ± 50 psi)		Press the brake pedal. The pressure should decrease to 12000 ± 1700 kPa (1750 ± 250 psi). The pressure should recover within two or three seconds.

( 1 )

N = Normal, M = Monitor, A = Action

Brake Line Pressure for Front Axle - Test for 735 (S/N: B1N1-1177)

Table 16

Status (1)	Description	Specification	Actual	Comments
	Brake Line Pressure	3450 ± 170 kPa (500 ± 25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Line Pressure for Front Axle - Test for 735 (S/N: B1N1178-UP)

Table 17

Status (1)	Description	Specification	Actual	Comments
	Brake Line Pressure	3800 ± 170 kPa (551 ± 25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Line Pressure for Center Axle - Test for 735 (S/N: B1N1-1177)

Table 18

Status (1)	Description	Specification	Actual	Comments
	Brake Line Pressure	3450 ± 170 kPa (500 ± 25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Line Pressure for Center Axle - Test for 735 (S/N: B1N1178-UP)

Table 19

Status (1)	Description	Specification	Actual	Comments
	Brake Line Pressure	3800 ± 170 kPa (551 ± 25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Release Pressure for Parking Brake - Test

Table 20

Status (1)	Description	Specification	Actual	Comments
	Release Pressure for Parking Brake Check	21000 ± 350 kPa (3050 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Accumulator (Service) - Test and Charge

Table 21

Status (1)	Description	Specification	Actual	Comments
	Service Brake Accumulator Test	5600 kPa (810 psi)		As successive service brake applications are made, the pressure readings will fall. The pressures will suddenly fall to zero. Specification is before falling to zero.

( 1 )

N = Normal, M = Monitor, A = Action

Brake Accumulator (Parking) - Test and Charge

Table 22

Status (1)	Description	Specification	Actual	Comments
	Parking Brake Accumulator Test	9600 ± 172 kPa (1400 ± 25 psi)		As successive parking brake applications are made, the pressure readings will fall. The pressures will suddenly fall to zero. Specification is before falling to zero.

( 1 )

N = Normal, M = Monitor, A = Action

Power Train Systems

ReferenceRefer to Testing & Adjusting, RENR5124, "Power Train" for more detail on the following test.

Torque Converter Inlet Pressure - Test for 735 S/N:B1N1-799

Table 23

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure for the Torque Converter Inlet (LOW IDLE)	125 ± 35 kPa (18 ± 5 psi)
	Relief Pressure for the Torque Converter Inlet (HIGH IDLE)	550 ± 35 kPa (80 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Inlet Pressure - Test for 735 S/N:B1N800-UP

Table 24

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure for the Torque Converter Inlet (LOW IDLE)	115 ± 20 kPa (17 ± 3 psi)
	Relief Pressure for the Torque Converter Inlet (HIGH IDLE)	530 ± 35 kPa (77 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pressure - Test for 735 S/N:B1N1-799

Table 25

Status (1)	Description	Specification	Actual	Comments
	Pressure for the Torque Converter Lockup Clutch (HIGH IDLE)	2550 ± 140 kPa (370 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pressure - Test for 735 S/N:B1N800-UP

Table 26

Status (1)	Description	Specification	Actual	Comments
	Pilot Pressure for the Torque Converter Lockup Clutch	2827 ± 138 kPa (410 ± 20 psi)
	Primary Pressure for the Torque Converter Lockup Clutch	965 ± 35 kPa (140 ± 5 psi)
	Pressure for the Torque Converter Lockup Clutch	1862 ± 70 kPa (270 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Lubrication Pressure - Test for 735 S/N:B1N1-799

Table 27

Status (1)	Description	Specification	Actual	Comments
	Pressure for Transmission Lubrication (LOW IDLE)	20 ± 14 kPa (3 ± 2 psi)
	Pressure for Transmission Lubrication (HIGH IDLE)	195 ± 35 kPa (28 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Lubrication Oil Pressure - Test for 735 S/N:B1N800-UP

Table 28

Status (1)	Description	Specification	Actual	Comments
	Pressure for Transmission Lubrication Oil (LOW IDLE)	32 ± 10 kPa (4.5 ± 1.5 psi)
	Pressure for Transmission Lubrication Oil (HIGH IDLE)	270 ± 15 kPa (39 ± 2 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Pressure - Test for 735 S/N:B1N1-799

Table 29

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure For The Transmission Hydraulic Control (LOW IDLE)	2345 ± 140 kPa (340 ± 20 psi)
	Relief Pressure For The Transmission Hydraulic Control (HIGH IDLE)	2550 ± 140 kPa (370 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Pressure - Test for 735 S/N:B1N800-UP

Table 30

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure For The Transmission Hydraulic Control (LOW IDLE)	2725 ± 70 kPa (395 ± 10 psi)
	Relief Pressure For The Transmission Hydraulic Control (HIGH IDLE)	3100 ± 70 kPa (450 ± 10 psi)
	Pilot Pressure For The Transmission Hydraulic Control	1655 ± 135 kPa (240 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Pump Pressure - Test for 735 S/N:B1N1-799

Table 31

Status (1)	Description	Specification	Actual	Comments
	Pressure at the Transmission Pump (LOW IDLE)	2550 ± 140 kPa (370 ± 20 psi)
	Pressure at the Transmission Pump (HIGH IDLE)	2345 ± 140 kPa (340 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Upshift Pressure - Test for 735 S/N:B1N800-UP

Table 32

Status (1)	Description	Specification	Actual	Comments
	Upshift Pressure	2690 ± 70 kPa (390 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Downshift Pressure - Test for 735 S/N:B1N800-UP

Table 33

Status (1)	Description	Specification	Actual	Comments
	Downshift Pressure	2690 ± 70 kPa (390 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Planetary Transmission Clutch Pressure - Test for 735 S/N:B1N1-799

Table 34

Status (1)	Description	Specification	Actual	Comments
	Pressure at the Planetary Transmission Clutches (HIGH IDLE)	2550 ± 140 kPa (370 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Output Transfer Gears and Differential System Pressure - Test for 735 S/N:B1N1-799

Table 35

Status (1)	Description	Specification	Actual	Comments
	Transfer Gear Lubrication and Differential Locks Pressure (HIGH IDLE)	240 ± 105 kPa (35 ± 15 psi)
	Supply Pressure for the Transfer Gear and Differential Locks (HIGH IDLE)	3445 ± 690 kPa (500 ± 100 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Output Transfer Gears and Differential System Pressure - Test for 735 S/N:B1N800-UP

Table 36

Status (1)	Description	Specification	Actual	Comments
	Transfer Gear Lubrication and Differential Locks Pressure (LOW IDLE)	Minimum 28 kPa (4 psi)
	Transfer Gear Lubrication and Differential Locks Pressure (HIGH IDLE)	Minimum 410 kPa (60 psi)
	Supply Pressure for the Transfer Gear and Differential Locks (HIGH IDLE)	2755 ± 345 kPa (400 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Axle Differential Lock Pressure - Test for 735 S/N:B1N1-799

Table 37

Status (1)	Description	Specification	Actual	Comments
	Axle Differential Lock Pressure (HIGH IDLE)	3445 ± 690 kPa (500 ± 100 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Axle Differential Lock Pressure - Test for 735 S/N:B1N800-UP

Table 38

Status (1)	Description	Specification	Actual	Comments
	Axle Differential Lock Pressure	2755 ± 345 kPa (400 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU7815, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Table 39

Status (1)	Description	Obtain	Comments
	Engine Oil Sample
	Engine Coolant Sample (Level I)
	Engine Coolant Sample (Level II)
	Hoist System and Brake System Oil Sample
	Steering System Oil Sample
	Differential & Final Drive Oil Samples
	Front Axle Housing Oil Sample
	Center Axle Housing Oil Sample
	Rear Axle Housing Oil Sample
	Left Front Final Drive Oil Sample
	Right Front Final Drive Oil Sample
	Left Center Final Drive Oil Sample
	Right Center Final Drive Oil Sample
	Left Rear Final Drive Oil Sample
	Right Rear Final Drive Oil Sample
	Torque Converter and Transmission Oil Sample
	Transfer Gear Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action