PM820, PM822, and PM825 Cold Planer TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar

Cold Planer

PM820 (S/N: HN81-UP; TLZ1-UP)

PM822 (S/N: JB71-UP; SL81-UP)

PM825 (S/N: HC81-UP; ESE1-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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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		Refer to Special Instruction, SEHS7633, "Battery Test Procedure".
	Charging System Test	18 VDC to 32 VDC		Refer to Testing and Adjusting, UENR3351, "Charging System Troubleshooting"
	Electric Starting System Test			Refer to Testing and Adjusting, UENR3351, "Electric Starting System - Test"

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

Engine

Cooling System

Table 2

Status(1)	Description	Specification	Actual	Comments
	Radiator Pressure Relief (Radiator Cap)(2)			Use 9S-8140 Pressurizing Pump to test the radiator pressure cap. 20 kPa (3 psi) more than the pressure marked on the cap.
	Freezing Point of Engine Coolant
	Conditioner Test of Engine Coolant
	Belt Tension	801 ± 44 N (180 ± 10 lb) for new belts. 645 ± 44 N (145 ± 10 lb) for used belts.		Auto Adjust Belt Tensioner
	Difference between the Upper and Lower Radiator Tank Temperatures

(1)	N = Normal, M = Monitor, A = Action
(2)	Test for the pressure that is listed on the cap.

Fuel System

(S/N: SL81-UP) (S/N: ESE1-UP) (S/N: TLZ1-UP)

Reference: Refer to Testing & Adjusting, UENR3351 .

Table 3

Status(1)	Description	Specification	Actual	Comments
	Fuel Pressure at 120 rpm to 180 rpm	50 kPa (7 psi)

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

Fuel System

(S/N: JB71-UP)

Reference: Refer to Testing & Adjusting, SENR9832 .

Table 4

Status(1)	Description	Specification	Actual	Comments
	Fuel Pressure at Low Idle	538 kPa (78 psi)
	Fuel Pressure at High Idle	641 kPa (93 psi)

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

Lubrication System

Table 5

Status(1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	107 kPa (16 psi)
	Engine Oil Pressure at High Idle	278 kPa (40 psi)

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

Basic Engine

Table 6

Status(1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle
	Engine Speed at High Idle
	Cylinder Cutout Test			Caterpillar Electronic Technician
	Engine Crankcase Pressure (Blowby)

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

Air Inlet and Exhaust System

Table 7

Status(1)	Description	Specification	Actual	Comments
	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

Travel Speed - Test

Table 8

Status(1)	Description	Specification	Actual	Comments
	Time required to complete the course in forward	17 to 19 seconds
	Time required to complete the course in reverse	17 to 19 seconds
	Maximum speed at high idle	100 ± 5 mpm (328 ± 15 fpm)

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

Auxiliary System

Reference: Refer to Testing & Adjusting, UENR6294 for more detail on the following test.

Relief Valve (Auxiliary) - Test and Adjust (Pump)

Table 9

Status(1)	Description	Specification	Actual	Comments
	Auxiliary pump pressure	21000 ± 500 kPa (3046 ± 73 psi)

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

Relief Valve (Auxiliary) - Test and Adjust (Auxiliary Power Unit)

Table 10

Status(1)	Description	Specification	Actual	Comments
	Auxiliary power unit relief pressure	16000 ± 200 kPa (2321 ± 29 psi)

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

Fan Pump - Test and Adjust

Table 11

Status(1)	Description	Specification	Actual	Comments
	Charge pressure	2400 ± 200 kPa (348 ± 29 psi)
	Case drain flow	7.6 L/min (2.0 US gpm) to 15.0 L/min (4.0 US gpm)

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

Main Relief Valve - Test and Adjust (Front Right Steering)

Table 12

Status(1)	Description	Specification	Actual	Comments
	Front right steering pressure	17500 ± 300 kPa (2538 ± 44 psi)

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

Fan Speed - Calibrate

Table 13

Status(1)	Description	Specification	Actual	Comments
	Fan pump output pressure	30000 ± 2000 kPa (4351 ± 290 psi)
	Fan speed with fan pump output pressure at 30000 ± 2000 kPa (4351 ± 290 psi)	1240 ± 10 RPM

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

Control Valve (Moldboard) Test and Adjust (Downward Pressure)

Table 14

Status(1)	Description	Specification	Actual	Comments
	Moldboard downward pressure	2000 kPa (290 psi)

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

Propel System

Reference: Refer to Testing & Adjusting, UENR6292 for more detail on the following test.

Propel Pump Pressure Override - Calibrate

Table 15

Status(1)	Description	Specification	Actual	Comments
	Pressure override relief valve setting	40000 kPa (5802 psi)

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

Relief Valve (Main, Propel Pump) - Test and Adjust

Table 16

Status(1)	Description	Specification	Actual	Comments
	Main relief pressure	43000 kPa (6237 psi)

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

Relief Valve (Charge) - Test and Adjust (Propel)

Table 17

Status(1)	Description	Specification	Actual	Comments
	Charge pressure	2800 ± 300 kPa (406 ± 44 psi)

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

Case Drain Flow for Piston Motor (Propel) - Test

Table 18

Status(1)	Description	Specification	Actual	Comments
	Case drain flow	Less than 6.6 L/min (1.7 US gpm)

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

Conveyor System

Reference: Refer to Testing & Adjusting, UENR6294 for more detail on the following test.

Relief Valve (Charge) - Test (Conveyor)

Table 19

Status(1)	Description	Specification	Actual	Comments
	Relief valve conveyor charge pressure	2800 ± 300 kPa (406 ± 44 psi)

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

Pressure reducing valve - Test and Adjust (Rear Side Plates)

Table 20

Status(1)	Description	Specification	Actual	Comments
	Side plate pressure	4500 ± 200 kPa (653 ± 29 psi)

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

Pressure Reducing Valve - Test and Adjust (Moldboard Lower)

Table 21

Status(1)	Description	Specification	Actual	Comments
	Moldboard lower pressure	14000 ± 600 kPa (2031 ± 87 psi)

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

Pressure Reducing Valve - Test and Adjust (Rotor Clutch)

Table 22

Status(1)	Description	Specification	Actual	Comments
	Rotor clutch pressure	4200 ± 200 kPa (609 ± 29 psi)

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

Pressure Reducing Valve - Test and Adjust (Track Tension)

Table 23

Status(1)	Description	Specification	Actual	Comments
	Track tension pressure	3500 ± 200 kPa (508 ± 29 psi)

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

Pressure Reducing Valve - Test and Adjust (Rotor Belt Tension)

Table 24

Status(1)	Description	Specification	Actual	Comments
	Belt tension pressure	5998 ± 200 kPa (870 ± 29 psi)

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

Pressure Reducing Valve - Test and Adjust (Auxiliary Brake Release)

Table 25

Status(1)	Description	Specification	Actual	Comments
	Auxiliary brake release pressure	3000 ± 200 kPa (435 ± 29 psi)

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

Pressure Reducing Valve - Test and Adjust (Front Side Plate)

Table 26

Status(1)	Description	Specification	Actual	Comments
	Side plate pressure	4500 ± 200 kPa (653 ± 29 psi)

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

Pressure Reducing Valve - Test and Adjust (Anti-slab Lower)

Table 27

Status(1)	Description	Specification	Actual	Comments
	Anti-slab lower pressure	5000 ± 200 kPa (725 ± 29 psi)

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

Pressure Reducing Valve - Test and Adjust (Left Grade Control Ski)

Table 28

Status(1)	Description	Specification	Actual	Comments
	Left grade control ski pressure	1000 ± 200 kPa (145 ± 29 psi)

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

Pressure Reducing Valve - Test and Adjust (Right Grade Ski Control)

Table 29

Status(1)	Description	Specification	Actual	Comments
	Right grade control ski pressure	1000 ± 200 kPa (145 ± 29 psi)

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

Conveyor (First Stage) - Test (Case Drain Flow for Piston Motor)

Table 30

Status(1)	Description	Specification	Actual	Comments
	Target case drain flow	Less than 8.0 ± 2.0 L/min (2.1 ± 0.5 US gpm)

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

Relief Valve (First Stage Conveyor) - Test and Adjust (Main)

Table 31

Status(1)	Description	Specification	Actual	Comments
	First stage relief	42000 ± 2000 kPa (6092 ± 290 psi)

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

Conveyor (Second Stage) - Test (Case Drain Flow for Piston Motor)

Table 32

Status(1)	Description	Specification	Actual	Comments
	Target case drain flow	Less than 8.0 ± 2.0 L/min (2.1 ± 0.5 US gpm)

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

Relief Valve (Second Stage Conveyor) - Test and Adjust

Table 33

Status(1)	Description	Specification	Actual	Comments
	Second stage relief	42000 ± 200 kPa (6092 ± 29 psi)

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

S·O·S Samples

Reference: Refer to Operation and Maintenance Manual, M0079944, "Maintenance Interval Schedule" for more detail on performing S.0.S samples.

Table 34

Status(1)	Description	Obtain		Comments
	Engine Oil Sample
	Engine Coolant Sample (Level II)
	Hydraulic Oil Sample
	Transmission Oil Sample
	Right Final Drive Oil Sample
	Left Final Drive Oil Sample
	Brake Fluid Oil Sample
	Power Steering Oil Sample

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