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

Off-Highway Truck/Tractor:

793B (S/N: 1HL1-UP)

793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-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	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, 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 # 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

ReferenceRefer to Testing & Adjusting, SENR6335, "793b Off-Highway Truck Hydraulic System" for more detail on the following tests.

ReferenceRefer to Testing & Adjusting, SENR1504, "793C and 793C XQ Off-Highway Trucks Hydraulic System"

ReferenceRefer to Testing & Adjusting, SENR1458, "793C Off-Highway Trucks Hydraulic System"

Hoist Cylinder Performance - Test (793B and 793C)

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) - Test and Adjust (793B)

Table 9

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Pressure for both the Lower and Raise Position	17240 ± 520 kPa (2500 ± 75 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Hoist Dual Stage) - Test and Adjust (793C)

Table 10

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Pressure Raise Position (High Pressure)	20370 kPa (2955 psi) to 21070 kPa (3057 psi)
	Relief Valve Pressure Lower Position (Low Pressure)	3450 kPa (500 psi) to 3800 kPa (550 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Gear Pump (Hoist and Rear Brake Cooling) Efficiency - Test (793B and 793C)

Table 11

Percent Flow Loss
{(A - B) ÷ C} x 100 = D
A	Pump flow at 690 kPa (100 psi)
B	Pump flow at 6900 kPa (1000 psi)
C	Pump flow at 690 kPa (100 psi)
D	Percent flow loss

Power Train System

ReferenceRefer to Testing & Adjusting, SENR6319, "793B Off-Highway Truck Power Train" for more detail on the following test.

ReferenceTesting & Adjusting, SENR1504, "793C Off-Highway Trucks Power Train"

Relief Valve (Torque Converter Outlet) Pressure - Test and Adjust (793B)

Table 12

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Pressure at Engine Speed of 1715 ± 65 RPM	138 ± 69 kPa (20 ± 10 psi) at low idle 551 ± 69 kPa (80 ± 10 psi) at high idle

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Torque Converter Outlet) Pressure - Test and Adjust (793C)

Table 13

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

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Torque Converter Inlet) Pressure - Test and Adjust (793B and 793C)

Table 14

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 Supply Pressure - Test and Adjust (793B)

Table 15

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Supply Pressure at LOW IDLE with Parking Brakes Engaged and Shift Control Lever in NEUTRAL	4690 ± 200 kPa (680 ± 29 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Signal Pressure - Test (793B)

Table 16

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Supply Pressure at MEDIUM IDLE	1725 kPa (250 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Signal Pressure - Test (793C)

Table 17

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Supply Pressure at MEDIUM IDLE1300 RPM	Above 2050 kPa (300 psi)
	Engine at Low IDLE electrical harness disconnected from the lockup clutch solenoid	0 kPa (0 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pilot Pressure - Test and Adjust (793B and 793C)

Table 18

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Pilot Pressure at LOW IDLE with Parking Brakes Engaged and Shift Control Lever in NEUTRAL	1725 ± 70 kPa (250 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Leakage - Test (793B and 793C)

Table 19

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 (793B)

Table 20

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Maximum Pressure at Engine Speed of 1300 rpm	2140 ± 70 kPa (310 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Maximum Pressure - Test (793C)

Table 21

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

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Primary Pressure - Test and Adjust (793B and 793C)

Table 22

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 - Test (793B and 793C)

Table 23

Transmission Speed	Engaged Clutches in the Transmission
Neutral-1	3
Neutral-2	1
Reverse	1 and 6
First speed	1 and 5
Second speed	2 and 5
Third speed	1 and 4
Fourth speed	2 and 4
Fifth speed	1 and 3
Sixth speed	2 and 3

Transmission Hydraulic Control Dual Stage Relief Valve Pressure - Test and Adjust (793B)

Table 24

Status (1)	Description	Specification	Actual	Comments
	Dual Stage Relief Valve, at LOW IDLE, Parking Brake Engaged, and Shift Control Lever in NEUTRAL-1	2515 kPa (365 psi) minimum
	Dual Stage Relief Valve, at MEDIUM IDLE (1300 RPM), and Parking Brake Engaged	2100 ± 105 kPa (305 ± 15 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control (Pressure Pack) - Test and Adjust (793C)

Table 25

Status (1)	Description	Specification	Actual	Comments
	Check Pressure for the Transmission Charge Pump Section in Torque Converter Drive Engine at low idle, parking brakes engaged, and transmission in the Neutral-1 position. All three harnesses for solenoids disconnected.	2515 kPa (365 psi) minimum
	Check Pressure in the Clutch Supply Rail in Direct Drive downshift solenoid activated and transmission in Neutral position. Engine at Medium Idle 1300 RPM	1724 ± 172 kPa (250 ± 25 psi)
	Check Pressure for the Transmission Charging Pump Section in Torque Converter All three harnesses for solenoids disconnected, engine at low idle, parking brakes engaged, and transmission in the Neutral-1 position Engine at high idle and transmission in the Neutral-1 position	2515 kPa (365 psi) minimum 3065 kPa (445 psi) when the machine is in torque converter drive

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust (793B)

Table 26

Speed	N-1	N-2	R	1	2	3	4	5	6
Engaged Clutches	3	1	1, 6	1, 5	2, 5	1, 4	2, 4	1, 3	2, 3
Stations	"C"	"B"	"B", "G"	"B", "F"	"A", "F"	"B ", "E"	"A", "E"	"B", "C"	"A", "C"

Table 27

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 28

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 29

(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.

Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust (793C)

Table 30

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 31

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 number 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 (793B)

Table 32

Speed	N-1	N-2	R	1	2	3	4	5	6
Engaged Clutches	3	1	1, 6	1, 5	2, 5	1, 4	2, 4	1, 3	2, 3
Stations	"C"	"B"	"B", "G"	"B", "F"	"A", "F"	"B ", "E"	"A", "E"	"B", "C"	"A", "C"

Table 33

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

( 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).

Transmission Hydraulic Control Clutch Pressure - Test (793C)

Table 34

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 35

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 36

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 (793B)

Table 37

Status (1)	Description	Specification	Actual	Comments
	Transmission Hydraulic Control Pilot Pressure, LOW IDLE, with Shift Control Lever in NEUTRAL	1755 ± 35 kPa (255 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Pilot Pressure - Test (793C)

Table 38

Status (1)	Description	Specification	Actual	Comments
	Transmission Hydraulic Control Pilot Pressure, LOW IDLE, with Shift Control Lever in NEUTRAL Parking Brakes Engaged	2415 kPa (350 psi) to 2760 kPa (400 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication Relief Valve (Transmission) Pressure - Test (793B and 793C

Table 39

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

( 1 )

N = Normal, M = Monitor, A = Action

Steering System

ReferenceRefer to Testing & Adjusting, SENR6338, "793B Off-Highway Truck Steering System" for more detail on the following test.

ReferenceRefer to Testing & Adjusting, SENR1452, "793C and 793C XQ Off-Highway Truck Steering System" for more detail on the following test.

Piston Pump (Steering) Pressure - Test and Adjust (793B)

Table 40

Status (1)	Description	Specification	Actual	Comments
	Cutoff Pressure (Accumulator Charging Valve)	21400 kPa (3100 psi)
	Cut-In Pressure (Accumulator Charging Valve)	19200 kPa (2785 psi)
	High Pressure Cutoff Valve (Pressure Compensator Valve) Engine at High Idle	23100 kPa (3350 psi)
	Low Pressure Cut-in Valve (Pressure Compensator Valve)	3600 kPa (522 psi) Maximum

( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Pressure - Test and Adjust (793C)

Table 41

Status (1)	Description	Specification	Actual	Comments
	Cutoff Pressure (Accumulator Charging Valve)	21400 ± 200 kPa (3100 ± 30 psi)
	Cut-In Pressure (Accumulator Charging Valve)	19200 ± 200 kPa (2785 ± 30 psi)
	High Pressure Cutoff Valve (Pressure Compensator Valve) Engine at High Idle	23100 ± 350 kPa (3350 ± 50 psi)
	Low Pressure Cut-in Valve (Pressure Compensator Valve)	3600 kPa (522 psi) Maximum

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering) - Test and Adjust (793B and 793C)

Table 42

Status (1)	Description	Specification	Actual	Comments
	Pressure Setting for the Steering Relief Valve	26000 ± 400 kPa (3770 ± 60 psi) at a flow of 8 L/min (2 US gpm)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Control Valve - Adjust (793B)

Table 43

Status (1)	Description	Specification	Actual	Comments
	Pressure Setting for the Steering Check and Relief Valve	27400 kPa (3980 psi) at a flow of 10 L/min (2.6 US gpm)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Control Valve - Adjust (793C)

Table 44

Status (1)	Description	Specification	Actual	Comments
	Pressure Setting for the Steering Check and Relief Valve	28500 ± 1000 kPa (4130 ± 150 psi) at a flow of 10 L/min (2.6 US gpm)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Accumulator - Test and Charge (793B and 793C)

Table 45

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

( 1 )

N = Normal, M = Monitor, A = Action

Braking System

ReferenceRefer to Testing & Adjusting, SENR6343, "793B Off-Highway Truck Air System and Brakes" for more detail on the following test.

ReferenceRefer to Testing & Adjusting, SENR1592, "793C and 793C XQ Off-Highway Truck Air System and Brakes" for more detail on the following test.

ReferenceRefer to Testing & Adjusting, SENR1454, "793C Off-Highway Truck Air System and Brakes" for more detail on the following test.

Service Brake Discs - Check (793B)

Table 46

Baseline Value for the Piston Stroke (1)
Front Wheels	Rear Wheels
4.4 mm (0.173 inch)	5.8 mm (0.228 inch)

( 1 )

The piston stroke that is measured through the service port. This value can float by 2 to 3 mm (0.0787 to 0.1181 inch) due to tolerances.

Table 47

Additional Piston Stroke (Compared to the Baseline Value for the Piston Stroke from Table 46)
Percent of Brake Wear	Front Brake Piston Travel	Rear Brake Piston Travel
10 percent	0.6 mm (0.0236 inch)	0.9 mm (0.0354 inch)
20 percent	1.2 mm (0.0472 inch)	1.8 mm (0.0708 inch)
30 percent	1.8 mm (0.0709 inch)	2.6 mm (0.1024 inch)
40 percent	2.4 mm (0.0945 inch)	3.5 mm (0.1378 inch)
50 percent	3.0 mm (0.1181 inch)	4.4 mm (0.1732 inch)
60 percent	3.5 mm (0.1378 inch)	5.3 mm (0.2087 inch)
70 percent	4.1 mm (0.1614 inch)	6.2 mm (0.2441 inch)
80 percent	4.7 mm (0.1850 inch)	7.0 mm (0.2756 inch)
90 percent	5.3 mm (0.2087 inch)	7.9 mm (0.3110 inch)
100 percent	5.9 mm (0.2323 inch)	8.8 mm (0.3465 inch)

Table 48

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 49

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 Brake Discs - Check (793C)

Table 50

Table For Determining The Wear Of Brake Disc Pack
Percent of Brake Wear	Front Brake Piston Travel	Rear Brake Piston Travel
0 percent	8.1 mm (0.32 inch)	6.9 mm (0.27 inch)
10 percent	8.9 mm (0.35 inch)	7.6 mm (0.30 inch)
20 percent	9.4 mm (0.37 inch)	8.4 mm (0.33 inch)
30 percent	10.2 mm (0.40 inch)	9.1 mm (0.36 inch)
40 percent	10.7 mm (0.42 inch)	9.9 mm (0.39 inch)
50 percent	11.4 mm (0.45 inch)	10.7 mm (0.42 inch)
60 percent	12.2 mm (0.48 inch)	11.4 mm (0.45 inch)
70 percent	12.7 mm (0.50 inch)	12.2 mm (0.48 inch)
75 percent	13.1 mm (0.52 inch)	12.6 mm (0.50 inch)
80 percent	13.5 mm (0.53 inch)	13.0 mm (0.51 inch)
90 percent	14.0 mm (0.55 inch)	13.7 mm (0.54 inch)
100 percent	14.7 mm (0.58 inch)	14.5 mm (0.57 inch)

Table 51

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 52

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 (793B and 793C)

Table 53

Status (1)	Description	Specification		Actual	Comments
		Retarder Control Lever Full ON	Retarder Control Lever Full OFF, Service Brake Applied
	Oil Pressure at Rear Slack Adjuster	Maximum Pressure of 3650 kPa (530 psi)	4345 kPa (630 psi) to 5445 kPa (790 psi)
	Oil Pressure at Front Slack Adjuster	3650 kPa (530 psi)	4345 kPa (630 psi) to 5445 kPa (790 psi)
	Air Pressure at Air/Hydraulic Cylinder	550 kPa (80 psi)	655 kPa (95 psi) to 827 kPa (120 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Show/hide table

NOTICE
Do not exceed the air pressure of 830 ± 35 kPa (120 ± 5 psi) or damage can occur to the air system components.

Slack Adjuster - Test and Adjust (793B and 793C)

Table 54

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 (793B and 793C)

Table 55

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 (Electric Drive Pump) - Adjust (793B and 793C S/N:4AR)

Table 56

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Pressure with engine start switch and the electric powered parking and secondary brake release pump switch in ON until the pressure stops rising	Minimum pressure of 3792 kPa (550 psi) Maximum pressure of 4481 kPa (650 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Brake Oil Cooler) - Test and Adjust (793C S/N:CBR, ; S/N:ATY, ; S/N:4GZ)

Table 57

Status (1)	Description	Specification	Actual	Comments
	Relief Valve Pressure with hoist control lever in the HOLD position	Maximum pressure of 790 ± 20 kPa (115 ± 3 psi)

( 1 )

N = Normal, M = Monitor, A = Action

S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU6519, "Maintenance Interval Schedule" for more detail on performing S.O.S. samples.

Table 58

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