- Off-Highway Truck/Tractor
- 797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-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.
Creating an Electronic Copy
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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). |
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Battery Test |
12.4 VDC or more |
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Refer to Special Instruction, SEHS7633, "Battery Test Procedure". |
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Charging System Test |
18 VDC to 32 VDC |
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Refer to Special Instruction, REHS0354, "Charging System Troubleshooting". |
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Electric Starting System Test |
12 to 16 V at −23° C (−10° F) to −7° C (19° F) |
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Refer to Testing and Adjusting, KENR9188, "Electric Starting System". |
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) |
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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) |
Test for the pressure that is listed on the cap. |
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Freezing Point of Engine Coolant |
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Conditioner Test of Engine Coolant |
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Belt Tension |
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Refer to Operation and Maintenance Manual. |
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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 Transfer Pressure |
724 kPa (105 psi) |
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Fuel Rail Pressure |
180000 kPa (26107 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Fuel System Operational Checks for 797F (S/N: LTZ1-UP)
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Table 4
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Fuel Transfer Pressure |
650 to 900 kPa (94 to 131 psi) |
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Fuel Rail Pressure |
180000 kPa (26107 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Lubrication System
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Table 5
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Engine Oil Pressure at Low Idle |
407 kPa (59 psi) |
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Engine Oil Pressure at High Idle |
627 kPa (91 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Basic Engine
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Table 6
Status(1) |
Description |
Specification |
Actual |
Comments |
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Engine Speed at Low Idle |
700 rpm |
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Engine Speed at High Idle |
1960 rpm |
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Torque Converter Stall Test Engine RPM |
1300 rpm |
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Cylinder Cutout Test |
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Caterpillar Electronic Technician |
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Engine Crankcase Pressure (Blowby) |
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(1) |
N = Normal, M = Monitor, A = Action |
Air Inlet and Exhaust System
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Table 7
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Stall Test Boost Pressure |
179 kPa (52.9 inch mercury)
to
242 kPa (71.5 inch mercury) |
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(1) |
N = Normal, M = Monitor, A = Action |
Performance Checks
Operational Checks
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Table 8
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Raise the Dump Body |
22 to 27 seconds |
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Lower the Dump Body |
16 to 21 seconds |
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Rear Suspension Group Ride Height |
203 ± 13 mm (8 ± 0.5 inch) |
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Front Suspension Group Ride Height |
254 ± 13 mm (10 ± 0.5 inch) |
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Toe Out Measurement |
B = A - 46.0 mm (1.81 inch) |
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(1) |
N = Normal, M = Monitor, A = Action |
Steering System
Reference: Refer to Testing & Adjusting, KENR8734, "797F Off-Highway Truck Steering System" for more detail on the following test.
Piston Pump (Steering) Pressure - Test
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Table 9
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Pressure cutoff valve test |
24115 ± 1379 kPa (3498 ± 200 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Steering) Pressure - Test
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Table 10
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Steering Relief Valve Pressure Test |
27580 ± 345 kPa (4000 ± 50 psi) |
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Steering Relief Valve Flow Test |
8 ± 2 L/min (2.1 ± 0.5 US gpm) |
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(1) |
N = Normal, M = Monitor, A = Action |
Steering Control Valve Pressure
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Table 11
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Steering Relief Valve Pressure Test |
28000 ± 1025 kPa (4065 ± 150 psi) |
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Steering Relief Valve Flow Test |
10 L/min (2.6 US gpm) |
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(1) |
N = Normal, M = Monitor, A = Action |
Accumulator
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Table 12
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Target Accumulator Charge Pressure |
7235 ± 345 kPa (1050 ± 50 psi) |
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Target Temperature |
21° C (70° F) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Hydraulic Fan System
Reference: Refer to Testing & Adjusting, KENR8746, "797F and 797F XQ Off-Highway Truck Hydraulic Fan System" for more detail on the following test.
Operational Checks for 797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)
Piston Pump (Hydraulic Fan) Pressure - Test
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Table 13
Status(1) |
Description |
Specification |
Actual |
Comments |
|
High Idle, Retarding, Downhill Haul, Low Altitude Arrangement |
Fan Speed: 530-550 rpm
25000 kPa (3625 psi) |
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High Idle, Retarding, Downhill Haul, High Altitude Arrangement |
Fan Speed: 580-600 rpm
25000 kPa (3625 psi) |
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High Idle, Retarding, Flat/Uphill Haul, Low Altitude Arrangement |
Fan Speed: 530-550 rpm
35000 kPa (5075 psi) |
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High Idle, Retarding, Flat/Uphill Haul, High Altitude Arrangement |
Fan Speed: 580-600 rpm
35000 kPa (5075 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Hydraulic System
Reference: Refer to Testing & Adjusting, KENR8381, "797F Off-Highway Truck Hydraulic System" for more detail on the following test.
Hoist Cylinder Performance - Test
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Table 14
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Cylinder Drift Test with empty dump body and hydraulic oil above 38° C (100° F) |
6.40 mm (0.25 inch) in 12.4 minutes |
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Hoist) - Test
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Table 15
Status(1) |
Description |
Specification |
Actual |
Comments |
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Relief Valve Test (High Pressure) with hoist in the RAISED position, engine at High Idle, and hydraulic oil temperature at 38° C (100° F) |
24200 ± 700 kPa (3510 ± 102 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Hoist Cylinder Head End) - Test
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Table 16
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief valve pressure (Low Idle) |
23800 ± 500 kPa (3452 ± 73 psi) |
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Relief valve pressure (High Idle) |
24200 ± 700 kPa (3510 ± 102 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Hoist Cylinder Rod End) - Test
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Table 17
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief valve pressure (High Idle) |
23200 ± 500 kPa (3365 ± 73 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Gear Pump (Hoist and Brake Cooling) Flow - Test
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Table 18
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Gear Pump Flow |
690 to 6900 kPa (100 to 1001 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Braking System
Reference: Refer to Testing & Adjusting, KENR8374, "797F and 797F XQ Off-Highway Truck Braking System" for more detail on the following test.
Brake Accumulator - Test
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Table 19
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Target Accumulator Charge Pressure |
6895 ± 345 kPa (1000 ± 50 psi) |
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Target Temperature |
21° C (70° F) |
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(1) |
N = Normal, M = Monitor, A = Action |
Brakes System Pressure - Test
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Table 20
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Brake System Cut-In Pressure at Low Idle |
14480 ± 483 kPa (2100 ± 70 psi) |
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Brake System Cutout Pressure at Low Idle |
20685 ± 483 kPa (3000 ± 70 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Main Relief Valve - Test
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Table 21
Status(1) |
Description |
Specification |
Actual |
Comments |
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Main Relief Valve Pressure at Low Idle, with accumulators at full charge |
23100 ± 345 kPa (3350 ± 50 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Brake Pilot Pressure (Foot Pedal) - Test
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Table 22
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Engine at Low Idle, with accumulators at full charge |
4950 ± 150 kPa (718 ± 22 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Brake Accumulator System Recovery - Test
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Table 23
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Transmission in PARK, Engine at Low Idle, Hoist lever in HOLD position. The lowest brake system pressure(2) |
9500 kPa (1380 psi) |
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The Accumulator recovery time |
12 Seconds |
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(1) |
N = Normal, M = Monitor, A = Action |
(2) |
The pressure for this test must be checked through Cat Electronic Technician (ET) |
Service Brakes and Retarder System Pressure - Test
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Table 24
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Service Brake Applied
Front and Rear Slack Adjuster |
6205 ± 275 kPa (900 ± 40 psi) |
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Manual Retarder Lever Applied
Front and Rear Slack Adjuster |
4135 to 6480 kPa (600 to 940 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Parking Brake Release Pressure - Test
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Table 25
Status(1) |
Description |
Specification |
Actual |
Comments |
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Parking Brake Release Pressure (Retarder Lever Applied, Transmission in N) |
4340 ± 480 kPa (630 ± 70 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Pressure Reducing Valve (Pilot Oil) - Test
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Table 26
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Pressure Reducing Valve (Pilot Oil) |
3790 ± 345 kPa (550 ± 50 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Parking Brake and Secondary Brake Release System Leakage - Test
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Table 27
Status(1) |
Description |
Specification |
Actual |
Comments |
|
System Pressure with no Plugged Wheels(2) |
690 kPa (100 psi) decrease in 1 minute |
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Plugged Rear Wheels System Pressure Check(1) |
690 kPa (100 psi) decrease in 1 minute |
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Plugged Front Wheels System Pressure Check(1) |
690 kPa (100 psi) decrease in 1 minute |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
If the oil pressure has not decreased in the first minute, then the leakage is not severe enough to affect the brake release system. |
Brake Cooling Pressure - Test
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Table 28
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Brake Cooling Pressure |
480 ± 340 kPa (70 ± 50 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Slack Adjuster - Test
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Table 29
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Oil Pressure for the front and rear wheels |
25 to 150 kPa (3.6 to 21.7 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Power Train System
Reference: Refer to Testing & Adjusting, KENR8371, "797F and 797F XQ Off-Highway Truck Power Train" for more detail on the following test.
Torque Converter Test
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Table 30
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Oil Temperature (during tests) |
> 80 °C (176 °F)
< 121 °C (250 °F) |
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Torque Converter Inlet Relief Pressure |
Low idle
145 ± 50 kPa (21 ± 7 psi) |
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High Idle
725 ± 105 kPa (105 ± 15 psi) |
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Torque Converter Outlet Relief Pressure |
Low idle
110 ± 50 kPa (16 ± 7 psi) |
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High idle
450 ± 105 kPa (65 ± 15 psi) |
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Maximum Torque Converter Stall RPM (2) |
1600 ± 65 RPM |
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Transmission Charge Pressure "R1N" and "JH5" Transmissions |
Low idle
2310 ± 138 kPa (335 ± 20 psi)
High idle
2650 ± 138 kPa (385 ± 20 psi) |
Low idle:
High idle: |
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Lockup Clutch Maximum Pressure
NEUTRAL/CONVERTER DRIVE/HIGH IDLE(3) |
0.0 ± 35 kPa (0.0 ± 5 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Torque Limiting strategy reduces engine RPM. |
(3) |
Lockup Clutch maximum pressure in DIRECT DRIVE is set during the transmission calibration procedure. |
Transmission Test
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Table 31
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Trans Oil Temperature (During Tests) |
80° to 120°C (176° to 248°F) |
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Main Relief Pressure (Low Idle) |
2310 ± 172 kPa (335 ± 25 psi) on "R1N" and "JH5" Transmission |
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(1) |
N = Normal, M = Monitor, A = Action |
Transmission Lubrication Pressures
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Table 32
Status(1) |
Transmission Pump and Lubrication Pressure for "R1N" and "JH5" Transmissions |
Engine Speed
Trans. Control |
Transmission Pump Pressure (Main Relief) |
Rear Box Lubrication Pressure |
Front Box Lubrication Pressure |
Comments |
Target |
Actual |
Target |
Actual |
Target |
Actual |
|
Low Idle
Trans. in Neutral |
2310 ± 138 kPa (335 ± 20 psi) |
|
90 ± 35 kPa (13 ± 5 psi) |
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70 ± 14 kPa (10 ± 2 psi) |
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Low Idle
Trans. in Reverse |
2310 ± 138 kPa (335 ± 20 psi) |
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90 ± 35 kPa (13 ± 5 psi) |
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70 ± 14 kPa (10 ± 2 psi) |
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Low Idle
Trans. in First, |
2310 ± 138 kPa (335 ± 20 psi) |
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90 ± 35 kPa (13 ± 5 psi) |
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70 ± 14 kPa (10 ± 2 psi) |
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High Idle
Trans. in First |
2650 ± 138 kPa (384 ± 20 psi) |
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550 ± 70 kPa (80 ± 10 psi) |
|
455 ± 70 kPa (66 ± 10 psi) |
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High Idle
Trans. in Fourth |
2650 ± 138 kPa (384 ± 20 psi) |
|
550 ± 70 kPa (80 ± 10 psi) |
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455 ± 70 kPa (66 ± 10 psi) |
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High Idle
Trans. in Sixth |
2650 ± 138 kPa (384 ± 20 psi) |
|
575 ± 70 kPa (83 ± 10 psi)(2) |
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455 ± 70 kPa (66 ± 10 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Machines S/N:LAJ263-UP are equipped with an updated lubrication manifold, and will show reduced lube pressure for clutches 6 and 7. For transmissions with an updated lubrication manifold, no lube test is now required for clutches 6 and 7. |
Transmission Clutch Pressures
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Table 33
Status(1) |
Transmission Clutch Pressures |
Gear |
Eng. Speed |
Lockup Clutch Press. |
Clutches Engaged and Pressures ± 138 kPa (± 20 psi) |
1 |
2 |
3 |
4 |
5 |
6 |
7 |
|
N |
Low Idle |
0 to 35 kPa (0 to 5 psi) |
|
2068 kPa (300 psi) |
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|
R |
Low Idle |
0 to 35 kPa (0 to 5 psi) |
|
2068 kPa (300 psi) |
|
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|
2310 kPa (335 psi)(2) |
|
1 |
Low Idle |
0 to 35 kPa (0 to 5 psi) |
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|
2068 kPa (300 psi) |
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|
2310 kPa (335 psi) |
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|
1 |
High Idle |
2137 ± 138 kPa (310 ± 20 psi) |
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|
1725 kPa (250 psi) |
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|
1930 kPa (280 psi) |
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|
2 |
High Idle |
2137 ± 138 kPa (310 ± 20 psi) |
|
1725 kPa (250 psi) |
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|
1930 kPa (280 psi) |
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3 |
High Idle |
2137 ± 138 kPa (310 ± 20 psi) |
1550 kPa (225 psi) |
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|
1930 kPa (280 psi) |
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4 |
High Idle |
2137 ± 138 kPa (310 ± 20 psi) |
|
1725 kPa (250 psi) |
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|
1930 kPa (280 psi) |
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|
5 |
High Idle |
2137 ± 138 kPa (310 ± 20 psi) |
1550 kPa (225 psi) |
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|
1930 kPa (280 psi) |
|
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|
6 |
High Idle |
2137 ± 138 kPa (310 ± 20 psi) |
|
1725 kPa (250 psi) |
|
1725 kPa (250 psi) |
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|
7 |
High Idle |
2137 ± 138 kPa (310 ± 20 psi) |
1550 kPa (225 psi) |
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|
1725 kPa (250 psi) |
|
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
"R1N" and "JH5" Transmissions |
Air System
Reference: Refer to Testing & Adjusting, KENR8748, "797F Off-Highway Truck Air System" for more detail on the following test.
Air Compressor
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Table 34
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Compressor recovery time from 585 kPa (85 psi) to 690 kPa (100 psi) |
40 seconds |
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|
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(1) |
N = Normal, M = Monitor, A = Action |
Air Compressor Governor - Test
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Table 35
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Cut-In Pressure |
655 kPa (95 psi) |
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Cut-Out Pressure |
837 ± 34 kPa (120 ± 5 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
S.O.S
Reference: Refer to Operation and Maintenance Manual, SEBU8417, "797F and 797F XQ Off-Highway Truck" for more detail on the following test.
Reference: Refer to Operation and Maintenance Manual, M0070546, "797F Off-Highway Truck" for more detail on the following test.
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Table 36
Status(1) |
Description |
Obtain |
Comments |
|
Cooling System Coolant Sample (Level 1) |
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|
Cooling System Coolant Sample (Level 2) |
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Differential and Final Drive Oil Sample |
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Engine Oil Sample |
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Front Wheel Oil Sample |
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Hydraulic System Oil Sample - Hoist and Brake System |
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Hydraulic System Oil Sample - Steering and Hydraulic Fan System |
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Torque Converter and Transmission Oil Sample |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |