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120H and 135H Motor Graders TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar


120H and 135H Motor Graders TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565}

Usage:

120H 5FM
Motor Grader
120H (S/N: 5FM1-799; 6TM1-365)
135H (S/N: 7MM1-248; 8WN1-349)

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.

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

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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, SENR3583, "Battery - Test". 
  Charging System Test      Refer to Testing and Adjusting, SENR3583, "Charging System - Test". 
  Electric Starting System Test      Refer to Testing and Adjusting, SENR3583, "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 1U-7297 Coolant/Battery Tester Gp or 1U-7298 Coolant/Battery Tester Gp. 
  Upper Radiator Tank Temperature and Lower Radiator Tank Temperature  -     
  Lower Radiator Tank Temperature  -     
  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 
  Minimum Fuel Pressure at LOW IDLE  50 kPa (7 psi)     
  Fuel Pressure at normal Load condition  200 kPa (29 psi) to 400 kPa (58 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  100 kPa (15 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 
  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 Testing and Adjusting, RENR1417, "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, SENR8518, "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)  2.8 ± 0.4     
  Blade Lift - Rod Out(2)  2.5 ± 0.4     
  Centershift - Rod In(2)  6.4 ± 1.1     
  Centershift - Rod Out(2)  6.2 ± 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)  2.6 ± 0.3     
  Blade Tip - Rod Out(2)  2.6 ± 0.4     
  Side Shift - Rod In(2)  9.0 ± 1.3     
  Side Shift - Rod Out(2)  9.1 ± 1.3     
  Scarifier - Rod In (if equipped)(2)  3.0 ± 0.4     
  Scarifier - Rod Out (if equipped)(2)  2.0 ± 0.3     
  Ripper (If Equipped) - Rod In(2)  5.4 ± 1.5     
  Ripper (If Equipped) - Rod Out(2)  4.1 ± 0.6     
  Articulation - Rod In(3)  3.9 ± 0.9     
  Articulation - Rod Out  3.9 ± 0.9     
  Blade Circle - 1/4 rotation  12.0 ± 1.4     
  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 60 Minutes  19 mm/ min (0.75 inch/ min) maximum     
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(1) N = Normal, M = Monitor, A = Action

Hydraulic and Steering System

Reference: Refer to Testing and Adjusting, SENR8518, "Hydraulic and Steering System" for more detail on the following tests.

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 ± 700 kPa (480 ± 100 psi)     
  True Low-Pressure Standby at HIGH IDLE  3100 ± 895 kPa (450 ± 130 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 ± 100 kPa (305 ± 15 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  24150 ± 350 kPa (3503 ± 51 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 ± 700 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

Steering System Pressure

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Table 15
Status(1)  Description  Specification  Actual  Comments 
  Maximum Steering Pressure  22100 ± 200 kPa (3205 ± 29 psi)     
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(1) N = Normal, M = Monitor, A = Action

Steering Accumulator Pressure and Precharge Check

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Table 16
Status(1)  Description  Specification  Actual  Comments 
  Maximum Steering Accumulator Pressure  19300 ± 690 kPa (2800 ± 100 psi)    The accumulator has a precharge of approximately 6900 kPa (1000 psi). 
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(1) N = Normal, M = Monitor, A = Action

Air and Brake System

Reference: Refer to Testing and Adjusting, RENR1417, "Air System and Brakes" for more detail on the following test.

Air Pressure Gauge - Test

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Table 17
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 18
Status(1)  Description  Specification  Actual  Comments 
  Cut IN, Pressure  790 ± 70 kPa (115 ± 10 psi)     
  Cut OUT, Pressure  965 ± 34 kPa (140 ± 5 psi)     
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(1) N = Normal, M = Monitor, A = Action

Pressure Switch (Low Brake Air) - Test

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Table 19
Status(1)  Description  Specification  Actual  Comments 
  Cut IN, Pressure  640 kPa (93 psi) Approximately     
  Cut OUT, Pressure  965 ± 34 kPa (140 ± 5 psi)     
  Low Brake Air Pressure Alarm Test  530 kPa (77 psi)     
  Low Brake Air Pressure - Indicator  530 kPa (77 psi)     
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(1) N = Normal, M = Monitor, A = Action

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

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Table 20
Status(1)  Description  Specification  Actual  Comments 
  Stop Lamp Brake Air Pressure Switch Test  45 kPa (7 psi) Approximately     
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(1) N = Normal, M = Monitor, A = Action

Power Train System

Reference: Refer to Testing and Adjusting, SENR8503, "Power Train" for more detail on the following test.

Transmission Charging Pump Pressure - Test and Adjust

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Table 21
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  3300 kPa (479 psi)(2)     
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(1) N = Normal, M = Monitor, A = Action
(2) Neutral position

Transmission Lubrication Oil Pressure - Test

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Table 22
Status(1)  Description  Specification  Actual  Comments 
  Transmission Lubrication Oil Pressure at HIGH IDLE in NEUTRAL position  558 ± 55 kPa (81 ± 8 psi)     
  Transmission Lubrication Oil Pressure at HIGH IDLE in FIRST GEAR FORWARD position  241 ± 27 kPa (35 ± 4 psi)     
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(1) N = Normal, M = Monitor, A = Action

Transmission Pressures - Test

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Table 23
Transmission Clutch Pressure with Differential Lock OFF 
Station  NEUTRAL Position at HIGH Idle  FIRST GEAR FORWARD Position at HIGH Idle  SECOND GEAR FORWARD Position at HIGH Idle  FIRST REVERSE GEAR Position at HIGH Idle 
(A)  0.0 kPa (.00 psi)  0.0 kPa (.00 psi)  0.0 kPa (.00 psi)  2255 ± 110 kPa (327 ± 16 psi) 
(B)  0.0 kPa (.00 psi)  2180 ± 95 kPa (316 ± 14 psi)  0.0 kPa (.00 psi)  0.0 kPa (.00 psi) 
(C)  0.0 kPa (.00 psi)  0.0 kPa (.00 psi)  2350 ± 95 kPa (341 ± 14 psi)  0.0 kPa (.00 psi) 
(D)  2670 ± 95 kPa (387 ± 14 psi)  0.0 kPa (.00 psi)  0.0 kPa (.00 psi)  0.0 kPa (.00 psi) 
(E)  0.0 kPa (.00 psi)  0.0 kPa (.00 psi)  1965 ± 110 kPa (285 ± 16 psi)  0.0 kPa (.00 psi) 
(F)  0.0 kPa (.00 psi)  2670 ± 90 kPa (387 ± 13 psi)  0.0 kPa (.00 psi)  2670 ± 90 kPa (390 ± 13 psi) 
(G)  2790 ± 85 kPa (405 ± 12 psi)  0.0 kPa (.00 psi)  0.0 kPa (.00 psi)  0.0 kPa (.00 psi) 
(H)  0.0 kPa (.00 psi)  1540 ± 85 kPa (223 ± 12 psi)  1540 ± 85 kPa (223 ± 12 psi)  1540 ± 85 kPa (223 ± 12 psi) 
Transmission Lubrication Pressure with Differential Lock OFF 
  NEUTRAL Position  FIRST GEAR FORWARD Position  SECOND GEAR FORWARD Position  FIRST REVERSE GEAR Position 
LOW Idle  80 ± 30 kPa (12 ± 4 psi)  7 kPa (1 psi) minimum  7 kPa (1 psi) minimum  7 kPa (1 psi) minimum 
HIGH Idle  340 kPa (50 psi)  241 ± 27 kPa (35 ± 4 psi)  241 ± 27 kPa (35 ± 4 psi)  241 ± 27 kPa (35 ± 4 psi) 
Transmission Lubrication Pressure with Differential Lock ON 
  NEUTRAL Position  FIRST GEAR FORWARD Position  SECOND GEAR FORWARD Position  FIRST REVERSE GEAR Position 
LOW Idle  80 ± 30 kPa (12 ± 4 psi)  7 kPa (1 psi) minimum  7 kPa (1 psi) minimum  7 kPa (1 psi) minimum 
HIGH Idle  340 kPa (50 psi)  241 ± 27 kPa (35 ± 4 psi)  241 ± 27 kPa (35 ± 4 psi)  241 ± 27 kPa (35 ± 4 psi) 

Drive Chain - Check

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Table 24
Status(1)  Description  Specification  Actual  Comments 
  Chain Pitch  44.5 mm (1.75 inch)     
  Number of Chain Links  14     
  New Measurement  622.3 mm (24.49 inch)     
  Measurement of Maximum Wear  641.1 mm (25.24 inch)     
  Chain Tension(2)  173 kg (381 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.

Differential Lock Pressure - Check

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Table 25
Status(1)  Description  Specification  Actual  Comments 
  Differential Lock Pressure  2620 kPa (380 psi) minimum     
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(1) N = Normal, M = Monitor, A = Action

S.O.S

Reference: Refer to Operation and Maintenance Manual, SEBU7059, "Maintenance Interval Schedule" for more detail on the following test.

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Table 26
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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