793D Off-Highway Truck TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar

Off-Highway Truck/Tractor

793D (S/N: FDB1-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.

Creating an Electronic Copy

Use the following procedure to create an editable electronic copy from SIS Web.

1. Click format to print.

2. Save the document as an HTML format.

3. Open the document with Microsoft Word.

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	Auto-tension		For fan drive. Alternator and air conditioner belts should deflect 13 to 19 mm (0.5 to 0.7 inch).
	Difference between the Upper Radiator Tank Temperature and Lower Radiator Tank Temperature	7° + 5° - 5° C (45° + 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	475 + 165 - 155 kPa (69 + 24 - 22 psi)

(1)	N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status(1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	324 + 276 - 174 kPa (47 + 40 - 25 psi)
	Engine Oil Pressure at High Idle	414 + 186 - 264 kPa (60 + 27 - 38 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	1960 ± 20 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	176.0 ± 26.4 kPa (25.5 ± 3.8 psi)
	Engine Speed	1721 ± 65 rpm
	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)
	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 Collapsed Exposed Chrome Length (Approximate)(2)	78.5 mm (3.0 inch)
	Front Suspension Collapsed Exposed Chrome length (Approximate)(2)	20 mm (0.79 inch)
	Toe Out Measurement	48.2 mm (1.90 inch)

(1)	N = Normal, M = Monitor, A = Action
(2)	Refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-Highway Trucks"

Hydraulic System

Reference: Refer to Testing & Adjusting, RENR8340, "Hydraulic System" 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	20370 to 21070 kPa (2955 to 3057 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
	Relief Valve Pressure	790 ± 20 kPa (115 ± 3 psi)

(1)	N = Normal, M = Monitor, A = Action

Power Train System

Reference: Refer to Testing & Adjusting, RENR8327, "Power Train" for more detail on the following test.

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

Table 11

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure at Engine Speed of 1672 ± 50 RPM	345 to 550 kPa (50 to 80 psi)

(1)	N = Normal, M = Monitor, A = Action

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

Table 12

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

(1)	N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Signal Pressure - Test

Table 13

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Supply Pressure at MEDIUM IDLE	Above 2050 kPa (300 psi)

(1)	N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pilot Pressure - Test and Adjust

Table 14

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

(1)	N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Leakage - Test

Table 15

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 Maximum Pressure - Test

Table 16

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Maximum Pressure at Engine Speed of 1300 rpm	2150 ± 2350 kPa (310 ± 340 psi)

(1)	N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Primary Pressure - Test and Adjust

Table 17

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

(1)	N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust

Table 18

Primary Clutch Pressure
Station(1)(2)		"A"	"B"	"C"	"E"	"F"	"G"
Clutch		No. 2	No. 1	No. 3	No. 4	No. 5	No. 6
Speed Position	Engaged Clutches	Pressure(3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)	Pressure (3)
NEUTRAL-1	3	0	0	480 kPa (70 psi)	0	0	0
NEUTRAL-1 (actual)	3
NEUTRAL-2	1	0	475 kPa (69 psi)	0	0	0	0
NEUTRAL-2 (actual)	1
REVERSE	1 and 6	0	475 kPa (69 psi)	0	0	0	425 kPa (62 psi)
REVERSE (actual)	1 and 6
FIRST	1 and 5	0	475 kPa (69 psi)	0	0	450 kPa (65 psi)	0
FIRST (actual)	1 and 5
SECOND	2 and 5	525 kPa (76 psi)	0	0	0	450 kPa (65 psi)	0
SECOND (actual)	2 and 5
THIRD	1 and 4	0	475 kPa (69 psi)	0	425 kPa (62 psi)	0	0
THIRD (actual)	1 and 4
FOURTH	2 and 4	525 kPa (76 psi)	0	0	425 kPa (62 psi)	0	0
FOURTH (actual)	2 and 4
FIFTH	1 and 3	0	475 kPa (69 psi)	480 kPa (70 psi)	0	0	0
FIFTH (actual)	1 and 3
SIXTH	2 and 3	525 kPa (76 psi)	0	480 kPa (70 psi)	0	0	0
SIXTH (actual)	2 and 3

(1)	Station "H" is not used.
(2)	Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station "D".
(3)	The tolerance is + 50 − 35 kPa (+ 7 − 5 psi).

Table 19

Shims For The Pressure Control Valve Pressure Change Per Shim(1)
Station(2)	A	B	C	D(3)	E	F	G
Clutch Engaged	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)	19 kPa (2.8 psi)	20 kPa (2.9 psi)	20 kPa (2.9 psi)	See the footnote below.(3)	17 kPa (2.5 psi)	19 kPa (2.7 psi)	19 kPa (2.8 psi)
6J-3993 Shim
0.25 mm (0.010 inch)	39 kPa (5.6 psi)	41 kPa (5.9 psi)	41 kPa (5.9 psi)	See the footnote below.(3)	35 kPa (5.1 psi)	37 kPa (5.3 psi)	39 kPa (5.6 psi)
4M-1751 Spacer
0.41 mm (0.016 inch)	62 kPa (9.0 psi)	65 kPa (9.4 psi)	65 kPa (9.4 psi)	See the footnote below(3).	56 kPa (8.1 psi)	59 kPa (8.6 psi)	62 kPa (9.0 psi)
5J-1036 Shim
0.80 mm (0.031 inch)	120 kPa (17.4 psi)	125 kPa (18.2 psi)	125 kPa (18.2 psi)	See the footnote below(3).	109 kPa (15.8 psi)	114 kPa (16.6 psi)	120 kPa (17.4 psi)

(1)	Do not change the amount of shims unless you are adjusting the primary pressure of the transmission clutches.
(2)	Station "H" is not used.
(3)	Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station "D".

Transmission Hydraulic Control Clutch Pressure - Test

Table 20

Clutch Pressure in Torque Converter Drive With The Engine At Low Idle rpm
Station(1)(2)		"A"	"B"	"C"	"E"	"F"	"G"
Clutch		No. 2	No. 1	No. 3	No. 4	No. 5	No. 6
Speed Position	Engaged Clutches	Pressure(3)	Pressure(3)	Pressure(3)	Pressure(3)	Pressure(3)	Pressure(3)
NEUTRAL-2	1	0	2400 kPa (348 psi)	0	0	0	0
NEUTRAL-2 (actual)	1
REVERSE	1 and 6	0	2400 kPa (348 psi)	0	0	0	2585 kPa (375 psi)
REVERSE (actual)	1 and 6
FIRST	1 and 5	0	2400 kPa (348 psi)	0	0	2585 kPa (375 psi)	0
FIRST (actual)	1 and 5

(1)	Station "H" is not used.
(2)	Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Power Train Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station "D".
(3)	The tolerance is + 240 − 100 kPa (+ 35 − 15 psi).

Table 21

Clutch Pressure in Torque Converter Drive With The Engine At High Idle rpm
Station(1)(2)		"A"	"B"	"C"	"E"	"F"	"G"
Clutch		No. 2	No. 1	No. 3	No. 4	No. 5	No. 6
Speed Position	Engaged Clutches	Pressure(3)	Pressure(3)	Pressure(3)	Pressure(3)	Pressure(3)	Pressure(3)
NEUTRAL-1	3	0	0	2470 kPa (358 psi)	0	0	0
NEUTRAL-1(actual)	3
NEUTRAL-2	1	0	2425 kPa (352 psi)	0	0	0	0
NEUTRAL-2 (actual)	1
REVERSE	1 and 6	0	2425 kPa (352 psi)	0	0	0	2805 kPa (407 psi)
REVERSE (actual)	1 and 6
FIRST	1 and 5	0	2425 kPa (352 psi)	0	0	2720 kPa (395 psi)	0
FIRST (actual)	1 and 5

(1)	Station "H" is not used.
(2)	Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Power Train Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station "D".
(3)	The tolerance is + 240 − 100 kPa (+ 35 − 15 psi).

Table 22

Clutch Pressure In Direct Drive With The Engine At High Idle rpm
Station(1)(2)		"A"	"B"	"C"	"E"	"F"	"G"
	Clutch	No. 2	No. 1	No. 3	No. 4	No. 5	No. 6
Speed Position	Engaged Clutches	Pressure(3)	Pressure(3)	Pressure(3)	Pressure(3)	Pressure(3)	Pressure(3)
FIRST	1 and 5	0	1724 kPa (250 psi)	0	0	1724 kPa (250 psi)	0
FIRST (actual)	1 and 5
SECOND	2 and 5	1724 kPa (250 psi)	0	0	0	1724 kPa (250 psi)	0
SECOND (actual)	2 and 5
THIRD	1 and 4	0	1724 kPa (250 psi)	0	1724 kPa (250 psi)	0	0
THIRD (actual)	1 and 4
FOURTH	2 and 4	1724 kPa (250 psi)	0	0	1724 kPa (250 psi)	0	0
FOURTH (actual)	2 and 4
FIFTH	1 and 3	0	1724 kPa (250 psi)	1724 kPa (250 psi)	0	0	0
FIFTH (actual)	1 and 3
SIXTH	2 and 3	1724 kPa (250 psi)	0	1724 kPa (250 psi)	0	0	0
SIXTH (actual)	2 and 3

(1)	Station "H" is not used.
(2)	Station "D" does not control a clutch. When the lockup clutch solenoid is activated, Station "D" reduces the pressure setting of the dual stage relief valve. The action of Station "D" on the ICM transmission hydraulic control maintains the oil in the clutch supply rail at a reduced pressure. Refer to the Power Train Testing and Adjusting, "Transmission Hydraulic Control (Pressure Pack) - Test and Adjust" for the proper procedure to adjust Station "D".
(3)	The tolerance is + 240 − 100 kPa (+ 35 − 15 psi).

Transmission Hydraulic Control Pilot Pressure - Test

Table 23

Status(1)	Description	Specification	Actual	Comments
	Transmission Hydraulic Control Pilot Pressure	2415 to 2760 kPa (350 to 400 psi)

(1)	N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Shift Signal Pressure - Test

Table 24

Status(1)	Description	Specification	Actual	Comments
	Transmission Hydraulic Control Shift Signal Pressure	2515 kPa (365 psi)

(1)	N = Normal, M = Monitor, A = Action

Lubrication Relief Valve (Transmission) Pressure - Test

Table 25

Status(1)	Description	Specification	Actual	Comments
	Lubrication Relief Valve (Transmission) Pressure at LOW IDLE	5 to 65 kPa (1 to 9 psi)
	Lubrication Relief Valve (Transmission) Pressure at HIGH IDLE	160 ± 50 kPa (23 ± 7.2 psi)

(1)	N = Normal, M = Monitor, A = Action

Steering System

Reference: Refer to Testing & Adjusting, RENR8336, "Steering System" for more detail on the following test.

Piston Pump (Steering) - Adjust

Table 26

Status(1)	Description	Specification	Actual	Comments
	Cutoff Pressure (Pressure Compensator Valve)	23100 ± 350 kPa (3350 ± 50 psi)

(1)	N = Normal, M = Monitor, A = Action

Relief Valve (Steering) - Test and Adjust

Table 27

Status(1)	Description	Specification	Actual	Comments
	Pressure Setting for the Steering Relief Valve	26000 ± 400 kPa (3770 ± 60 psi)

(1)	N = Normal, M = Monitor, A = Action

Steering Control Valve - Adjust

Table 28

Status(1)	Description	Specification	Actual	Comments
	Pressure Setting for the Steering Check and Relief Valve	28500 ± 1000 kPa (4130 ± 150 psi)

(1)	N = Normal, M = Monitor, A = Action

Solenoid Valve and Manifold (Rear Axle Fan, Lubrication, Steering) - Adjust

Table 29

Status(1)	Description	Specification	Actual	Comments
	Pressure Setting for the (Priority Valve) Solenoid Valve and Manifold (Rear Axle Fan, Brake Cooling, Drive Motor, Lubrication, and Steering)	18300 ± 520 kPa (2650 ± 75 psi)

(1)	N = Normal, M = Monitor, A = Action

Steering Accumulator - Test and Charge

Table 30

Status(1)	Description	Specification	Actual	Comments
	Charging Pressure for the Steering Accumulator	6550 ± 350 kPa (950 ± 50 psi)

(1)	N = Normal, M = Monitor, A = Action

Braking System

Reference: Refer to Testing & Adjusting, RENR8330, "Air System and Brakes" for more detail on the following test.

Service Brake Discs - Check - Standard

Table 31

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 32

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 Pressure - Test

Table 33

Status(1)	Description	Specification		Actual	Comments
		Retarder Control Lever Full ON	Retarder Control Lever Full OFF
	Oil Pressure at Rear Slack Adjuster	3461 to 4371 kPa (502 to 634 psi)(2)	4323 to 5461 kPa (627 to 792 psi)(2)
	Oil Pressure at Front Brakes	3461 to 4371 kPa (502 to 634 psi)(3)	4323 to 5461 kPa (627 to 792 psi)(3)
		2724 to 3440 kPa (395 to 499 psi)(4)	3406 to 4302 kPa (494 to 624 psi)(4)
	Air Pressure at Rear Brake Master Cylinder	524 to 662 kPa (76 to 96 psi)(2)	655 to 827 kPa (95 to 120 psi)(2)

(1)	N = Normal, M = Monitor, A = Action
(2)	For both the Extended Life Wheel and Brake Group configuration and the Standard Wheel and Brake Group configuration.
(3)	For Standard Wheel and Brake Group configuration.
(4)	For Extended Life Wheel and Brake Group configuration.

Slack Adjuster - Test and Adjust

Table 34

Status(1)	Description	Specification	Actual	Comments
	Residual Pressure at the Rear Wheels	65 kPa (9.4 psi)
	Residual Pressure at the Front Wheels	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 35

Status(1)	Description	Specification	Actual	Comments
	Brake Cooling Pressure at LOW IDLE	14 kPa (2 psi)
	Brake Cooling Pressure at HIGH IDLE	172 kPa (25 psi)

(1)	N = Normal, M = Monitor, A = Action

Relief Valve (Brake Oil Cooler) - Test and Adjust

Table 36

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

(1)	N = Normal, M = Monitor, A = Action

S.O.S

Reference: Refer to Operation and Maintenance Manual, SEBU7792, "Maintenance Interval Schedule" for more detail on performing S.O.S. samples.

Table 37

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