MH3049 Material Handler TA2 Technical Inspection{7000} Caterpillar


MH3049 Material Handler TA2 Technical Inspection{7000}

Usage:

MH3049 HPB
Material Handler:
MH3049 (S/N: HPB1-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

Use the following procedure to create an editable electronic copy from SIS Web.

  1. Click format to print.

  1. Save the document as an HTML format.

  1. 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 (2)     12.4 VDC or more            
    Charging System Test (3)     18 VDC to 32 VDC            
    Electric Starting System Test (4)     12 to 16 V at −23° C (−10° F) to
−7° C (19° F)    
       
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
( 2 ) Refer to Special Instruction, SEHS7633, "Battery Test Procedure".
( 3 ) Refer to Special Instruction, REHS0354, "Charging System Troubleshooting".
( 4 ) Refer to Testing and Adjusting, RENR2415, "Electric Starting System - Test".

Engine

Cooling System

Table 2
Status (1)     Description     Specification     Actual     Comments    
    Radiator Pressure Relief (Radiator Cap) (2)     -         Refer to System Operation Testing and Adjusting.    
    Freezing Point of Engine Coolant     -         Refer to Operation and Maintenance Manual.    
    Conditioner Test of Engine Coolant     -         Refer to Operation and Maintenance Manual.    
    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

Table 3
Status (1)     Description     Specification     Actual     Comments    
    Fuel Pressure at Rated Speed    
455 kPa (66 psi) to
579 kPa (84 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Lubrication System

Table 4
Status (1)     Description     Specification     Actual     Comments    
Oil Pressure at Rated Speed
275 kPa (40 psi) to
414 kPa (60 psi)    
       
    Oil Pressure at Low Idle     Approximately
124 kPa (18 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Basic Engine

Table 5
Status (1)     Description     Specification     Actual     Comments    
New Rebuild Service Limit    
    Engine Performance - Test (Engine Speed)        
    No Load High Idle
AEC OFF
0 to 3 seconds    
1800 ± 50 rpm     1800 + 50 - 200 rpm            
    No Load High Idle
AEC OFF
> 3 seconds    
1700 ± 50 rpm     1700 + 50 - 200 rpm
   
       
    No Load High Idle
AEC ON    
950 ± 50 rpm     950 ± 50 rpm            
    No Load Low Idle
AEC OFF    
950 ± 50 rpm     950 ± 50 rpm            
    Maximum Speed with Load
Pump stall condition    
1800 ± 50 rpm     ≥ 1600 rpm            
( 1 ) N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

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

Performance Checks

ReferenceRefer to Testing & Adjusting, KENR7985, "Performance Tests" for more detail on the following test.

Operation Checks

Cylinder Drift - Check

Table 7
"Cylinder Drift - Check"    
Status (1)     Description     Specification (2)     Actual     Comments    
    Boom     Extension    
19 mm (0.75 inch)    
       
    Stabilizers     Extension    
3.175 mm (0.125 inch)    
       
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Cylinder Operating Speed (seconds)

Hydraulic System

ReferenceRefer to Testing & Adjusting, UENR2876 for more detail on the following tests.

Pilot System

Relief Valve (Pilot) - Test

Table 8
"Relief Valve (Pilot) - Test"    
Status (1)     Description     Specification     Actual     Comments    
    Relief Valve (Pilot)    
4,0680 kPa (590 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action

Pump System

Margin Pressure - Test and Adjust

Table 9
"Margin Pressure - Test and Adjust"    
Status (1)     Description     Specifications (2)     Actual     Comments    
    Left Pump     Main Pump Pressure    
2,000 to 2,068 kPa (290 to 300 psi)    
       
    Load Sensing Signal Pressure    
    Margin Pressure (3)    
    Right Pump     Main Pump Pressure    
2,275 to 2,344 kPa (330 to 340 psi)    
       
    Load Sensing Signal Pressure    
    Margin Pressure (3)    
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Engine at Idle (790 rpm)
( 3 ) Margin pressure is the difference between main pump pressure tap and load sensing signal pressure tap.

Main Control Valve

Pressure Reducing Valve (Signal Limiter) - Test and Adjust

Table 10
"Pressure Reducing Valve (Signal Limiter) - Test and Adjust"    
Status (1)     Description     Specifications (2)     Actual     Comments    
    Boom Cylinder     Extend     Maximum (3)            
    Boom Cylinder     Retract    
6,895 to 10,342 kPa (1,000 to 1,500 psi)    
       
    Stick Cylinder     Extend     Maximum (3)            
    Stick Cylinder     Retract     Maximum (3)            
    Grapple Cylinder (Close) (4)     Extend    
22,753 to 24,132 kPa (3,300 to 3,500 psi)    
       
    Grapple Cylinder (Open) (4)     Retract    
13,790 ± 15,168 kPa (2,000 ± 2,200 psi)    
       
    Grapple (Rotate) (4)     CCW    
15,169 kPa (2,200 psi)    
       
    Cab Lift Cylinder (Up/(Down)     Extend/Retract    
23,442. kPa (3,400 psi)    
       
    Cab Lift Cylinder (For/Aft)     Extend/Retract    
23,442. kPa (3,400 psi)    
       
    Steering Cylinder     Left    
21,029 kPa (3,050 psi)    
       
    Steering Cylinder     Right    
21,029 kPa (3,050 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Engine at High Idle (1500 rpm)
( 3 ) The signal limiter pressure reducing valve is set to the same pressure as the line relief valve.
( 4 ) The pressure setting can very depending on the model of grapple that is being used.

Relief Valve (Hydraulic Oil Warming) - Test and Adjust

Table 11
"Relief Valve (Hydraulic Oil Warming) - Test and Adjust"    
Status (1)     Description     Specifications (2)     Actual     Comments    
    Load Sense Pressure    
17,582 to 18,271 kPa (2,550 ± 2,650 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) The engine speed will be adjusted to a medium idle (1200 rpm) by the IQAN monitor when the "Warm Up Speed" has been engaged.

Swing System

Swing Brake Pressure - Test

Table 12
"Swing Brake Pressure - Test"    
Status (1)     Description     Specifications (2)     Actual     Comments    
    Swing Brake Pressure    
2,068 to 2,413 kPa (300 to 350 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Engine at Idle (790 rpm)

Relief Valve (Swing Charge Pressure) - Test and Adjust

Table 13
"Relief Valve (Swing Charge Pressure) - Test and Adjust"    
Status (1)     Description     Specifications (2)     Actual     Comments    
    Left Swing    
2,413 to 2,758 kPa (350 to 400 psi)    
       
    Right Swing        
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Engine at Idle (790 rpm)

Relief Valve (Swing Pump) - Test and Adjust

Table 14
"Relief Valve (Swing Pump) - Test and Adjust"    
Status (1)     Description     Specifications (2)     Actual     Comments    
    Left Swing    
36,542 to 36,887 kPa (5,300 to 5,350 psi)    
       
    Right Swing        
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Engine at Idle (790 rpm)

Return System

Relief Valve (Hydraulic Fan) - Test

Table 15
"Relief Valve (Hydraulic Fan) - Test"    
Status (1)     Description     Specifications (2)     Actual     Comments    
    Hydraulic Fan Relief    
17,926 to 18,271 kPa (2,600 to 2,650 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Engine at High Idle (1500 rpm)

Hydraulic System Pressure - Test and Adjust

Table 16
"Hydraulic System Pressure - Test and Adjust"    
Status (1)     Description     Specifications (2)     Actual     Comments    
    Rear Back Pressure Manifold    
517 to 552 kPa (75 to 80 psi)    
       
    Front Back Pressure Manifold    
793 to 827 kPa (115 to 120 psi)    
       
( 1 ) N = Normal, M = Monitor, A = Action
( 2 ) Engine at Idle (790 rpm)

S.O.S

Table 17
Status (1)     Description     Obtain     Comments    
    Engine Oil Sample            
    Engine Coolant Sample (Level II)            
    Hydraulic Oil Sample            
    Swing Drive Oil Sample            
    Right Final Drive Oil Sample            
    Left Final Drive Oil Sample            
( 1 ) N = Normal, M = Monitor, A = Action

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