854G Wheel Dozer TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar

Wheel Dozer

854G (S/N: AMP1-UP; A4W1-UP; 1JW1-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

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 ± 1V		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, RENR1309, "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	-
	Conditioner Test of Engine Coolant	-
	Belt Tension	-		Refer to Operation and Maintenance Manual.
	Difference between the Upper and Lower Radiator Tank Temperatures	-
	Aftercooler Water Outlet Temperature

(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	415 kPa (60 psi) to 450 kPa (65 psi)

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

Lubrication System

Table 4

Status(1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	140 kPa (20 psi)
	Engine Oil Pressure at Full Load Speed	345 kPa (50 psi)

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

Basic Engine

Table 5

Status(1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle
	Engine Speed at High Idle
	Torque Converter Stall Test Engine RPM
	Cylinder Cutout Test	-		Cat® Electronic Technician (Cat ET Service Tool

(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
	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)	-

(1)	N = Normal, M = Monitor, A = Action
(2)	Compare the exhaust temperature variance at each exhaust port.

Hydraulic Performance Checks

Reference: Refer to Testing & Adjusting, RENR2127, "Hydraulic System" for more detail on the following test.

Lift Cylinder and Tilt Cylinder (Tilt, Tip Function) Drift - Check

Table 7

Status(1)	Description	Specification	Actual	Comments
	Lift Cylinder	Max. Drift 38.1 mm (1.5 inch) at oil temperature of 38° to 49°C (100° to 120°F) for 5 minutes
		Max. Drift 38.1 mm (1.5 inch) at oil temperature of 50° to 65°C (122° to 149°F) for 2.7 minutes
		Max. Drift 38.1 mm (1.5 inch) at oil temperature of above 66° C (150° F) for 1.7 minutes
	Tilt Cylinder	Max. Drift 11.2 mm (0.44 inch) at oil temperature of 38° to 49°C (100° to 120°F) for 5 minutes
		Max. Drift 11.2 mm (0.44 inch) at oil temperature of 50° to 65°C (122° to 149°F) for 2.7 minutes
		Max. Drift 11.2 mm (0.44 inch) at oil temperature of above 66° C (150° F) for 1.7 minutes

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

Lift and Tilt Cylinder Speed - Check

Table 8

Status(1)	Description	Specification	Actual	Comments
	Time needed to move the tilt cylinder rod from the fully retracted position to the fully extended position	5.1 seconds
	Time needed to move the tilt cylinder rod from the fully extended position to the fully retracted position	4.2 seconds
	Time needed to move the lift cylinder rod from the fully extended position to the fully retracted position (Blade fully lowered to blade fully raised)	6.5 seconds

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

Brake Performance Checks

Reference: Refer to Testing and Adjusting, SENR1353, "Braking System" for more detail on the following test.

Table 9

Status(1)	Description	Specification	Actual	Comments
	Brake Accumulator - Test (Test from OMM)	Apply the service brake pedal and release the service brake pedal. The rate for this process is 1 second on and 1 second off. Do this process until the alert indicator for brake oil pressure comes on. This process will decrease the accumulator pressure. A minimum of five applications of the service brake pedal are required with new discs
	Service Brake Holding Ability Test- Test (Test from OMM)	Start the engine. Raise the implement slightly. Apply the service brake. Release the parking brake. Move the transmission control to THIRD SPEED FORWARD while the service brakes are applied. Make sure that the autoshift control is in the OFF position. Gradually increase the engine speed to high idle. The machine should not move.
	Parking Brake Holding Ability Test- Test (Test from OMM)	Move the transmission control to THIRD SPEED FORWARD. Make sure that the autoshift control is in the OFF position. The parking brake indicator light should come on. Gradually increase the engine speed to high idle. The machine should not move.

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

Steering Performance Checks

Reference: Refer to Testing & Adjusting, SENR1373, "Steering System" for more detail on the following test.

Steering Time - Check and Adjust

Table 10

Status(1)	Description	Specification	Actual	Comments
	Left Steering Time (High Idle)	4.4 ± 0.3 seconds
	Right Steering Time (High Idle)	4.4 ± 0.3 seconds
	Left Steering Time (Low Idle)	7.4 ± 0.6 seconds
	Right Steering Time (Low Idle)	7.4 ± 0.6 seconds
	Left/Right Time Difference (Max) (When the service brakes are not applied)	0.3 seconds
	Left/Right Time Difference (Max) (When the service brakes are applied)	0.2 seconds

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

Hydraulic System

Reference: Refer to Testing & Adjusting, RENR2127, "Hydraulic System" for more detail on the following test.

Relief Valve (Pilot) - Test and Adjust

Table 11

Status(1)	Description	Specification	Actual	Comments
	Pilot Oil Pressure at Low Idle	2400 ± 100 kPa (350 ± 15 psi)

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

Relief Valve (Lift Cylinder) - Test and Adjust

Table 12

Status(1)	Description	Specification	Actual	Comments
	Lift Cylinder Relief Valve Pressure at High Idle	22675 ± 125 kPa (3290 ± 20 psi)
	Main Relief Valve Pressure	22675 ± 125 kPa (3290 ± 20 psi)

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

Relief Valve (Tilt, Tip Cylinder) - Test and Adjust

Table 13

Status(1)	Description	Specification	Actual	Comments
	Tilt Cylinder Relief Valve Pressure at High Idle	24560 ± 50 kPa (3560 ± 10 psi)
	Relief Valve Pressure for Tilt and Tip Circuit	24560 ± 50 kPa (3560 ± 10 psi)

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

Torque Converter Stall (3FWD) - Test

Table 14

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed (3FWD) - Minimum(2)	1690 RPM
	Torque Converter Stall Speed (3FWD) - Nominal(2)	1720 RPM
	Torque Converter Stall Speed (3FWD) - Maximum(2)	1750 RPM

(1)	N = Normal, M = Monitor, A = Action
(2)	Check the stall speed with the hydraulic fan at maximum speed.

Torque Converter Stall and Implement Pump Double Stall - Test

Table 15

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall and Implement Pump Double Stall Speed - Minimum(2)	1425 RPM
	Torque Converter Stall and Implement Pump Double Stall Speed - Nominal(2)	1475 RPM
	Torque Converter Stall and Implement Pump Double Stall Speed - Maximum(2)	1525 RPM

(1)	N = Normal, M = Monitor, A = Action
(2)	Check the stall speed with the hydraulic fan at maximum speed.

Piston Pump Margin Pressure (Hydraulic Fan) - Test and Adjust

Table 16

Status(1)	Description	Specification	Actual	Comments
	Control Pressure	4650 to 9050 kPa (675 to 1310 psi)
	Margin Pressure	2000 ± 100 kPa (290 ± 15 psi)

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

Power Train System

Reference: Refer to Testing & Adjusting, SENR1347, "Power Train" for more detail on the following test.

Torque Converter Lockup Clutch Pressure - Test

Table 17

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Inlet Pressure (High Idle)	Maximum pressure with cold oil is 930 kPa (135 psi)
	Torque Converter Outlet Pressure (High Idle)	Maximum Pressure is 550 kPa (80 psi) Minimum Pressure is 415 kPa (60 psi)
	Lockup Clutch Pressure (If equipped)	Stabilized pressure with an activated solenoid is 2000 to 2137 kPa (290 to 310 psi). Pressure is less than 170 kPa (25 psi)when the solenoid is not activated.

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

Torque Converter Stall (1FWD) - Test

Table 18

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed (1FWD) - Minimum(2)	1555 RPM
	Torque Converter Stall Speed (1FWD) - Nominal(2)	1585 RPM
	Torque Converter Stall Speed (1FWD) - Maximum(2)	1615 RPM

(1)	N = Normal, M = Monitor, A = Action
(2)	Check the stall speed with the hydraulic fan at maximum speed.

Torque Converter Stall (3FWD) - Test

Table 19

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed (3FWD) - Minimum(2)	1690 RPM
	Torque Converter Stall Speed (3FWD) - Nominal(2)	1720 RPM
	Torque Converter Stall Speed (3FWD) - Maximum(2)	1750 RPM

(1)	N = Normal, M = Monitor, A = Action
(2)	Check the stall speed with the hydraulic fan at maximum speed.

Transmission Pressures - Test and Adjust

Table 20

Status(1)	Description	Specification	Actual	Comments
	Speed Clutch P1 Pressure (High Idle) (Initial Pressure)	530 ± 35 kPa (77 ± 5 psi) when the direction switch is in the NEUTRAL position and plug (K) for the load piston is removed
	Speed Clutch P1 Pressure (Low Idle)	480 kPa (70 psi) below the pressure at high idle. Plug (K) for the load piston is installed.
	Speed Clutch P1 Pressure (High Idle)	2515 ± 140 kPa (365 ± 20 psi) when the direction switch is in FORWARD or in REVERSE and any speed is selected. Plug (K) for the load piston is installed.
	Direction Clutch P2 Pressure (Low Idle)	380 ± 35 kPa (55 ± 5 psi) lower than the speed clutch pressure at pressure tap (E). Plug (K) for the load piston is installed.
	Direction Clutch P2 Pressure (High Idle)	380 ± 35 kPa (55 ± 5 psi) lower than the speed clutch pressure at pressure tap (E). Plug (K) for the load piston is installed.
	Transmission Lubrication Oil Pressure (High Idle)	172 ± 27 kPa (25 ± 4 psi)

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

Steering System

Reference: Refer to Testing & Adjusting, SENR1373, "Steering System" for more detail on the following test.

Relief Valve (Steering Pilot) - Test and Adjust

Table 21

Status(1)	Description	Specification	Actual	Comments
	Steering Pilot Pump at High Idle	2400 ± 100 kPa (350 ± 15 psi)
	Primary Steering Pump Pilot Pressure at High Idle	1650 ± 150 kPa (240 ± 20 psi)

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

Steering System Pressure (High Pressure Stall) - Test and Adjust

Table 22

Status(1)	Description	Specification	Actual	Comments
	Steering System Pressure at High Idle (High Pressure Stall)	31000 kPa (4500 psi)

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

Piston Pump (Steering) Low Pressure Standby - Test and Adjust

Table 23

Status(1)	Description	Specification	Actual	Comments
	Piston Pump (Steering) Low Pressure Standby	2000 to 5000 kPa (290 to 725 psi)

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

Piston Pump (Steering) Margin Pressure - Test and Adjust

Table 24

Status(1)	Description	Specification	Actual	Comments
	Piston Pump (Steering) Margin Pressure	2100 kPa (305 psi)

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

Relief Valve (Steering Cylinder Crossover) - Test and Adjust

Table 25

Status(1)	Description	Specification	Actual	Comments
	Steering Cylinder Crossover Relief Valve Pressure	31000 ± 700 kPa (4500 ± 100 psi)

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

Relief Valve (Pump Backup) - Test and Adjust

Table 26

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure	24160 ± 700 kPa (3500 ± 100 psi)
	Backup Relief Valve Pressure	34500 ± 700 kPa (5000 ± 100 psi)

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

Relief Valve (Secondary Steering) - Test and Adjust - If Equipped

Table 27

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure	17300 ± 700 kPa (2509 ± 100 psi)

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

Steering Neutralizer Valve - Check and Adjust

Table 28

Status(1)	Description	Specification	Actual	Comments
	Right Side Gap (Engine Frame to Non-Engine Frame	19 ± 3 mm (0.75 ± 0.12 inch)
	Left Side Gap (Engine Frame to Non-Engine Frame	19 ± 3 mm (0.75 ± 0.12 inch)

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

Brake and Hydraulic Fan System

Reference: Refer to Testing & Adjusting, SENR1353, "Braking System" for more detail on the following test.

Piston Pump (Brake) Pressure - Test and Adjust

Table 29

Status(1)	Description	Specification	Actual	Comments
	Piston Pump Pressure	16000 ± 345 kPa (2320 ± 50 psi)(2)
		13790 ± 345 kPa (2000 ± 50 psi)(3)

(1)	N = Normal, M = Monitor, A = Action
(2)	For 854G S/N:1JW1-237
(3)	For 854G S/N:AMP1-UP, ; S/N:1JW238-UP, and ; S/N:A4W1-UP

Service Brake System Pressure - Test

Table 30

Status(1)	Description	Specification	Actual	Comments
	Rear Service Brake Pressure (Brake ON)	4520 ± 386 kPa (656 ± 55 psi)
	Front Service Brake Pressure (Brake ON)	4310 ± 350 kPa (625 ± 50 psi)

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

Parking Brake System Pressure - Test

Table 31

Status(1)	Description	Specification	Actual	Comments
	Parking Brake System Pressure	6035 ± 515 kPa (875 ± 75 psi)

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

S·O·S Samples

Reference: Refer to Operation and Maintenance Manual, SEBU7979, "854G Wheel Dozer", "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Reference: Refer to Operation and Maintenance Manual, SEBU7142, "854G Wheel Dozer", "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Engine Oil Sample

Table 32

Status(1)	Description	Obtain	Comments
	Engine Oil Sample

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

Engine Coolant Sample

Table 33

Status(1)	Description	Obtain	Comments
	Engine Coolant Sample

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

Hydraulic Oil Sample

Table 34

Status(1)	Description	Obtain	Comments
	Hydraulic Oil Sample

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

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 35

Status(1)	Description	Obtain	Comments
	Front Differential & Final Drive Oil Sample
	Rear Differential & Final Drive Oil Sample

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

Differential & Final Drive Oil Samples (Outboard Final Drives)

Table 36

Status(1)	Description	Obtain	Comments
	Front Differential Oil Sample
	Rear Differential Oil Sample
	Left Front Final Drive Oil Sample
	Right Front Final Drive Oil Sample
	Left Rear Final Drive Oil Sample
	Right Rear Final Drive Oil Sample

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

Transmission/Torque Converter Oil Sample

Table 37

Status(1)	Description	Obtain	Comments
	Transmission/Torque Converter Oil Sample

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