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120K Series 2 Motor Grader TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar


120K Series 2 Motor Grader TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565}

Usage:

120K 2 SZS
Motor Grader
120K Series 2 (S/N: SZS1-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

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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  12.45 VDC or more    Refer to Testing and Adjusting, SENR9939, "Battery - Test". 
  Charging System Test  28 ± 1 V    Refer to Testing and Adjusting, SENR9939, "Charging System - Test". 
  Electric Starting System Test      Refer to Testing and Adjusting, SENR9939, "Electric Starting System - Test". 
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(1) N = Normal, M = Monitor, A = Action

Engine

Cooling System

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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  -    Use 245-5829 Coolant/Battery Tester Gp. 
  Conditioner Test of Engine Coolant  -    Use 245-5829 Coolant Conditioner Test Kit. 
  Belt Tension  534 ± 111 N (120 ± 25 lb) for new belts
400 ± 90 N (90 ± 5 lb) for used belts 		   Auto- Adjust Belt Tensioner 
  Upper Radiator Tank Temperature and Lower Radiator Tank Temperature  6° to 11° C (43° to 52° F)     
  Lower Radiator Tank Temperature  8° to 22° C (46 ° to 72 ° F)     
  Jacket Water Inlet Temperature from Cooling System  -     
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(1) N = Normal, M = Monitor, A = Action
(2) Test for the pressure that is listed on the cap.

Fuel System

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Table 3
Status(1)  Description  Specification  Actual  Comments 
  Fuel Pressure at LOW IDLE  400 to 435 kPa (58 to 63 psi)     
  Fuel Pressure at Normal Load Condition  400 to 525 kPa (58 to 76 psi)     
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(1) N = Normal, M = Monitor, A = Action

Lubrication System

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Table 4
Status(1)  Description  Specification  Actual  Comments 
  Engine Oil Pressure at LOW IDLE  275 kPa (40 psi)     
  Engine Oil Pressure at HIGH IDLE  600 kPa (87 psi)     
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(1) N = Normal, M = Monitor, A = Action

Basic Engine

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Table 5
Status(1)  Description  Specification  Actual  Comments 
  Engine Speed at LOW IDLE       
  Engine Speed at HIGH IDLE       
  Cylinder Cutout Test       
  Engine Crankcase Blowby Pressure       
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(1) N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

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Table 6
Status(1)  Description  Specification  Actual  Comments 
  Boost Pressure Test  96 kPa (14 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)  -     
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(1) N = Normal, M = Monitor, A = Action
(2) Compare the exhaust temperature variance at each exhaust port.

Performance Checks

Brake Performance Checks

Reference: Refer to Operation and Maintenance Manual, KENR8415, "Braking System - Test" for more detail on the following test.

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Table 7
Status(1)  Description  Perform  Comments 
  Service Brake Test     
  Parking Brake Test     
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(1) N = Normal, M = Monitor, A = Action

Hydraulic Performance Checks

Reference: Refer to Testing and Adjusting, KENR8413, "Hydraulic and Steering System" for more detail on the following tests.

Cylinder Cycle Time - Check

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Table 8
Status(1)  Description  Specification  Actual  Comments 
  Blade Lift - Rod In(2)  2.9 ± 0.4     
  Blade Lift - Rod Out(2)  2.9 ± 0.4     
  Centershift - Rod In(2)  6.6 ± 1.1     
  Centershift - Rod Out(2)  6.3 ± 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)  2.7 ± 0.4     
  Blade Tip - Rod Out(2)  2.7 ± 0.4     
  Side Shift - Rod In(2)  9.2 ± 1.4     
  Side Shift - Rod Out(2)  9.3 ± 1.3     
  Scarifier - Rod In (if equipped)(2)  4.2 ± 0.6     
  Scarifier - Rod Out (if equipped)(2)  2.8 ± 0.4     
  Ripper (If Equipped) - Rod In(2)  6.3 ± 0.9     
  Ripper (If Equipped) - Rod Out(2)  4.8 ± 0.7     
  Articulation - Rod In(3)  4.0 ± 0.5     
  Articulation - Rod Out  4.0 ± 0.5     
  Blade Circle - 1/4 rotation  12.2 ± 1.5     
  Steering Wheel - Number of Turns  6 to 7     
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(1) N = Normal, M = Monitor, A = Action
(2) Cycle times are for a "running distance" of 305 mm (12 inch).
(3) 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.

Cylinder Cycle Time - Check

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Table 9
Status(1)  Description  Specification  Actual  Comments 
  Cylinder Drift Per Minute  3.0 mm/ min (0.12 inch/ min) Maximum     
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(1) N = Normal, M = Monitor, A = Action

Hydraulic and Steering System

Reference: Refer to Testing and Adjusting, KENR8413, "Hydraulic and Steering System" for more detail on the following test.

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

Low Standby Pressure Adjustment

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

Adjustment for Flow Compensator (Margin Pressure)

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Table 11
Status(1)  Description  Specification  Actual  Comments 
  Flow Compensator (Margin Pressure) at HIGH IDLE  2100 ± 150 kPa (305 ± 22 psi)     
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(1) N = Normal, M = Monitor, A = Action

Adjustment for Hydraulic System Pressure

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Table 12
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)  
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(1) N = Normal, M = Monitor, A = Action

Adjustment for Signal Network

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Table 13
Status(1)  Description  Specification  Actual  Comments 
  Signal Network Pressure at HIGH IDLE  3300 ± 689 kPa (480 ± 100 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Implement) - Test and Adjust

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Table 14
Status(1)  Description  Specification  Actual  Comments 
  Relief Valve Pressure  27600 ± 400 kPa (3900 ± 60 psi)     
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(1) N = Normal, M = Monitor, A = Action

Disc Pack Preload for Circle Drive - Adjust

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Table 15
Status(1)  Description  Specification  Actual  Comments 
  Spring Deflection  2.30 ± 0.25 mm (0.091 ± 0.010 inch)     
  Minimum thickness to reuse clutch disk  2.14 mm (0.084 inch)     
  Minimum thickness to reuse clutch disk  0.20 mm (0.008 inch)     
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(1) N = Normal, M = Monitor, A = Action

Steering Wheel Slip - Check

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Table 16
Status(1)  Description  Specification  Actual  Comments 
  Maximum Steering Pressure  18616 ± 689 kPa (2700 ± 100 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Steering) - Test and Adjust

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Table 17
Status(1)  Description  Specification  Actual  Comments 
  Relief Valve (Steering) - Test and Adjust  22100 ± 200 kPa (3205 ± 29 psi)     
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(1) N = Normal, M = Monitor, A = Action

Air and Brake System

Reference: Refer to Testing and Adjusting, KENR8415, "Air System and Brakes" for more detail on the following test.

Air Pressure Gauge - Test

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Table 18
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     
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(1) N = Normal, M = Monitor, A = Action

Air Compressor Governor - Test and Adjust

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Table 19
Status(1)  Description  Specification  Actual  Comments 
  Cut IN, Pressure  793 ± 34 kPa (115 ± 5 psi)     
  Cut OUT, Pressure  1000 ± 34 kPa (145 ± 5 psi)     
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(1) N = Normal, M = Monitor, A = Action

Pressure Switch (Low Brake Air) - Test

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Table 20
Status(1)  Description  Specification  Actual  Comments 
  Cut IN, Pressure  530 ± 40 kPa (77 ± 6 psi) Approximately     
  Cut OUT, Pressure  1000 ± 34 kPa (145 ± 5 psi)     
  Low Brake Air Pressure Alarm Test  530 ± 40 kPa (76.87120 ± 5.80160 psi)     
  Low Brake Air Pressure - Indicator  640 kPa (93 psi)     
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(1) N = Normal, M = Monitor, A = Action

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

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Table 21
Status(1)  Description  Specification  Actual  Comments 
  Stop Lamp Brake Air Pressure Switch Test  60 kPa (9 psi) Approximately     
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(1) N = Normal, M = Monitor, A = Action

Limit Switch (Service Brake) - Test and Adjust

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Table 22
Status(1)  Description  Specification  Actual  Comments 
  Dimension for Adjustment of the Limit Switch  18.0 ± 2.0 mm (0.71 ± 0.08 inch)     
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(1) N = Normal, M = Monitor, A = Action

Power Train System

Reference: Refer to Testing and Adjusting, KENR8427, "Power Train" for more detail on the following test.

Transmission Charging Pump Pressure - Test and Adjust for 120K Series 2 S/N:SZS1-488

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Table 23
Status(1)  Description  Specification  Actual  Comments 
  Transmission Charging Pump Pressure at LOW IDLE  2750 ± 70 kPa (399 ± 10 psi)(2)     
  Transmission Charging Pump Pressure at HIGH IDLE  3150 ± 150 kPa (457 ± 22 psi)(2)     
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(1) N = Normal, M = Monitor, A = Action
(2) Neutral position

Power Train Charge System Pressure - Test and Adjust for 120K Series 2 S/N:SZS489-UP

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Table 24
Status(1)  Description  Specification  Actual  Comments 
  Transmission Charging Pump Pressure at 800 RPM  2610 ± 70 kPa (379 ± 10 psi)(2)     
  Transmission Charging Pump Pressure at 2000 RPM  2835 ± 70 kPa (411 ± 10 psi)(2)     
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(1) N = Normal, M = Monitor, A = Action
(2) Neutral position

Transmission Lubrication Oil Pressure - Test for 120K Series 2 S/N:SZS1-488

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Table 25
Status(1)  Description  Specification  Actual  Comments 
  Transmission Lubrication Oil Pressure at HIGH IDLE in NEUTRAL position  517 ± 172 kPa (75 ± 25 psi)     
  Transmission Lubrication Oil Pressure at HIGH IDLE in FIRST GEAR FORWARD position  152 ± 48 kPa (22 ± 7 psi)     
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(1) N = Normal, M = Monitor, A = Action

Transmission Lubrication Oil Pressure - Test for 120K Series 2 S/N:SZS489-UP

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Table 26
Status(1)  Description  Specification  Actual  Comments 
  Transmission Lubrication Oil Pressure in NEUTRAL position at 2000 RPM  643 ± 228 kPa (93 ± 33 psi)     
  Transmission Lubrication Oil Pressure in FIRST GEAR FORWARD position at 2000 RPM  179 ± 48 kPa (26 ± 7 psi)     
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(1) N = Normal, M = Monitor, A = Action

Transmission Pressures - Test 120K Series 2 S/N:SZS1-488

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Table 27
Status(1)  Description  Specification  Actual  Comments 
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 1 (First Gear, Forward)  2265 ± 95 kPa (329 ± 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)  2295 ± 95 kPa (333 ± 14 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 4 (Second Gear, Forward)  2055 ± 150 kPa (298 ± 22 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 5 (Neural)  2888 ± 132 kPa (419 ± 19 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 6 (First Gear, Forward or Reverse)  2740 ± 115 kPa (397 ± 17 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 7 (First Gear, Forward or Reverse) or (Second, Forward)  2675 ± 140 kPa (388 ± 20 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 8 (Neutral)  2680 ± 130 kPa (389 ± 19 psi)     
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(1) N = Normal, M = Monitor, A = Action

Transmission Pressures - Test for 120K Series 2 S/N:SZS489-UP

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Table 28
Status(1)  Description  Specification  Actual  Comments 
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 1 (First Gear, Forward)  2758 ± 69 kPa (400 ± 10 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 2 (Second Gear, Forward)  2758 ± 69 kPa (400 ± 10 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 3 (First Gear, Reverse)  2758 ± 69 kPa (400 ± 10 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 4 (Second Gear, Forward)  2758 ± 69 kPa (400 ± 10 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 5 (Neural)  2758 ± 69 kPa (400 ± 10 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 6 (First Gear, Forward or Reverse)  2758 ± 69 kPa (400 ± 10 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 7 (First Gear, Forward or Reverse) or (Second, Forward)  2758 ± 69 kPa (400 ± 10 psi)     
  Transmission Clutch Pressure with Differential Lock OFF at Clutch 8 (Neutral)  2758 ± 69 kPa (400 ± 10 psi)     
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(1) N = Normal, M = Monitor, A = Action

Drive Chain - Check for 120K Series 2

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Table 29
Status(1)  Description  Specification  Actual  Comments 
  Chain Pitch  50.8 mm (2.00 inch)     
  Number of Chain Links  12     
  New Measurement  609.6 mm (24 inch)     
  Measurement of Maximum Wear  628.7 mm (25 inch)     
  Chain Tension(2)  277 kg (611 lb)     
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(1) N = Normal, M = Monitor, A = Action
(2) The chain is put into tension in order to displace oil between the components of the chain. This will help to ensure metal-to-metal contact between the components. This will also ensure an accurate measurement.

Tandem - Check for 120K Series 2

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Table 30
Status(1)  Description  Specification  Actual  Comments 
  Tandem - Check  5.0 mm (0.12 inch)     
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(1) N = Normal, M = Monitor, A = Action

Differential Lock Pressure - Check

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Table 31
Status(1)  Description  Specification  Actual  Comments 
  Differential Lock Pressure  2410 kPa (350 psi) minimum     
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(1) N = Normal, M = Monitor, A = Action

Clutch Control - Test for 120K Series 2 S/N:SZS1-488

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Table 32
Status(1)  Description  Specification  Actual  Comments 
Clutch Not Depressed Clutch Depressed
  First Gear FORWARD  2265 ± 180 kPa (329 ± 26 psi) minimum  0 to 21 kPa (0 to 3 psi)     
  Second Gear FORWARD  2350 ± 95 kPa (341 ± 14 psi)  0 to 21 kPa (0 to 3 psi)     
  First Gear REVERSE  2295 ± 150 kPa (333 ± 22 psi)  0 to 21 kPa (0 to 3 psi)     
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(1) N = Normal, M = Monitor, A = Action

Clutch Control - Test for 120K Series 2 S/N:SZS489-UP

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Table 33
Status(1)  Description  Specification  Actual  Comments 
Clutch Not Depressed Clutch Depressed
  First Gear FORWARD  2758 ± 69 kPa (400 ± 10 psi)  0 to 21 kPa (0 to 3 psi)     
  Second Gear FORWARD  2758 ± 69 kPa (400 ± 10 psi)  0 to 21 kPa (0 to 3 psi)     
  First Gear REVERSE  2758 ± 69 kPa (400 ± 10 psi)  0 to 21 kPa (0 to 3 psi)     
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(1) N = Normal, M = Monitor, A = Action

S.O.S

Reference: Refer to Operation and Maintenance Manual, SEBU8250, "Maintenance Interval Schedule" for more detail on the following test.

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Table 34
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)     
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(1) N = Normal, M = Monitor, A = Action

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