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TA-2 Visual & Technical Inspection for Motor Grader

SMCS - Job Code - 540 Component Code - 753T

Cat dealer Customer


Address Address
Contact Contact

Serial Number : 2FM Inspector : Temperature :


Model : 160H Work Order : Time :
Engine S/N: SMU: Date :
Manufacturer : Unit Location:

Note: Review Machine & S·O·S History and check for Active Service Letters prior to inspection.

Status of the Machine


Normal
The status recommendation of your Motor Grader is:
Visual Inspection for Motor Grader
Status assessment ü– Normal M – Monitor A – Action Blank – Not Applicable

1. Prepare Machine Inspection


# Status Description Comments
1.1 Check with customer for operator complaints

1.2 Prepare the machine for the inspection

1.3 Perform walk-around Inspection

1.4 Download machine fault codes

1.5 1.5 Check Product Link https://productsupportglobalcontent.cat.com/cda/files/712700/7/Product%20Link%20Dealer%20Validation.pdf

Is machine equipped with PL?

Is PL activated?

Is PL functioning properly?

1.6 Observe engine exhaust colors

1.7 Listen for unusual noises

1.8

1.9

1.10

Item No. Additional Comment


2. Lower-Level Inspection
Status Description Comments
2.1 Tires and rims

2.2 Front Wheels & Spindles/Wheel Drives

2.3 Axle Arms & Kingpins

2.4 Wheel Lean Cylinder & Lean Bar

2.5 Front Axle

2.6 Steering Cylinders, Tie Rods & Linkages

2.7 Articulation Joints & Bearings

2.8 Secondary Steering Pump & Motor

2.9 Brake & Fan Hydraulic Pump & Control Valve

2.10 Drive Shaft & Parking Brake

2.11 Front & Rear Machine Frames

2.12 Bottom Guard

2.13 Transmission & Parking Brake

2.14 Tandem Drives, Service Brakes & Wheels

2.15 Final Drives

2.16 Rear Differential Housing

2.17

2.18

2.19

Item No. Additional Comment


3. Middle Level Inspection
Status Description Comments
3.1 Work Lights

3.2 Rear Brake & Directional Lights

3.3 Steps & Handrails

3.4 Fuel Tank

3.5 Articulation Cylinders

3.6 Cab Mounts

3.7 Cab Exterior

3.8 Service Brakes & Parking Brake Accumulators

3.9 Cooling Fan & Hydraulic Motor

3.10 Implement & AWD Control Valve

3.11 Implement & Steering Control Valves

3.12 Hood & Platform

3.13 AWD Hydraulic Pump

3.14 Engine Oil Pan

3.15

3.16

3.17

Item No. Additional Comment


4. Upper-Level Inspection
Status Description Comments

4.1 Upper Radiator, Air Inlet, Oil Cooler & Aftercooler Lines

4.2 Lower Radiator, Aftercooler & Condenser Lines

4.3 Radiator, Oil Cooler, Condenser & Aftercooler

4.4 Radiator Cap

4.5 Hydraulic Tank

4.6 Batteries & Battery Cables

4.7 Fuel System Lines, Fuel Pumps & Filter Bases

4.8 Cylinder Head & Valve Cover

4.9 Intake Manifold

4.10 Engine & Transmission Mounts

4.11 Transmission Oil Cooler


Pulleys, Belts, Water Pump, Compressor Clutch &
4.12
Alternator
4.13 Precleaner & Air Cleaner

4.14 Turbocharger

4.15 Exhaust Manifold

4.16 Transmission, Parking Brake & Power Train Pumps

4.17 Cab Interior

4.18

4.19

4.20

Item No. Additional Comment


5. Implement/Attachment Inspection
Status Description Comments
5.1 Moldboard & Blade

5.2 Blade Sideshift Cylinder

5.3 Blade Tip Cylinder

5.4 Circle Gears

5.5 Circle Drive Motor

5.6 Circle Drive Swivel

5.7 Blade Lift Cylinder & Lock Bars

5.8 Centershift Cylinder

5.9 Centershift Lock

5.10 Blade Cushion Accumulator

5.11 Drawbar

5.12 Ripper/Scarifier Lift Cylinder

5.13 Ripper/Scarifier

5.14

5.15

5.16

Item No. Additional Comment

Other Remarks
Technical Inspection for Motor Grader
Status assessment ü- Normal M - Monitor A - Action Blank – Not Applicable
NOTE: Prior to making any system adjustments, please consult the Service Information System (SIS) for the latest specifications.
1. Engine
1.1 Cooling System
Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.1.1 Radiator Pressure Relief (Radiator Cap) - - - Test for pressure listed on radiator cap

1.1.2 1.1.2 Test Engine Coolant

Check Freezing Point of Engine Coolant - - - Use 245-5829 Coolant/Battery Tester/Refractometer.

Test Engine Coolant Conditioner - - - Use 8T-5296 Conditioner Test Kit.

Alternator, Fan Drive, Air Conditioner V-belts should deflect 14 to 20 mm under


1.1.3 Check Belt Tension - - -
110 N of force.
1.1.4 Engine Coolant Temperature 89 3 3 From test specification 0K9629.
C
1.1.5 Radiator Temperature Drop (In - Out) 6 5 5 From test specification 0K9629.
C

1.2 Fuel System


*Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.2.1 1.2.1 Engine Speed - Check

No Load at Low Idle 800 10 10 From test specification 0K9629.


RPM
No Load at High Idle 2210 60 60 From test specification 0K9629.
RPM
1.2.2 1.2.2 Fuel System Pressure - Test

Fuel Pressure at Low Idle - - -

Fuel Pressure at High Idle 288 110 90 From test specification 0K9629.
KPA
1.3 Lubrication System
*Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.3.1 1.3.1 Engine Oil Pressure - Test

Oil Pressure at Low Idle 170 430 60 From test specification 0K9629.
KPA
Oil Pressure at High Idle 340 260 140 From test specification 0K9629.
KPA
1.4 Basic Engine
*Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.4.1 Cylinder Cutout Test - - -

1.4.2 Engine Crankcase Pressure (Blowby) - Test - - - See Tables tab for Blowby Tools.

1.5 Air Inlet and Exhaust System


*Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.5.1 Boost Pressure Test (Adjusted Boost Pressure from TMI) 91.5 13.8 13.8 Adj Boost at TC RPM from test specification 0K9629.
KPA
1.5.2 Exhaust Temperature - Test (Measure at Each Cylinder) Units Cyl Observed Cyl Observed
Observed #1 #2
#2 #3 #4
#4 #5 #6
1.6 Miscellaneous Engine
*Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.6.1

1.6.2

1.6.3

2. Performance Checks
2.1 Brake Performance Checks
Status Description Units Observed Max Min Comments
2.1.1 Service Brake Test (Test from OMM) - - See Service Brake Test in Tables tab.

2.1.2 Parking Brake Test (Test from OMM) - - See Parking Brake Test in Tables tab.

2.2 Secondary Steering Performance Checks


*Status Description Units Observed Max Min Comments
2.2.1 2.2.1 Secondary Steering Test (Test from T&A Secondary Steering)

Three Second Powerup Test - -

- Secondary Steering Response Test

Steer Right (Stop to Stop) - -

Steer Left (Stop to Stop) - -


2.3 Hydraulic Performance Checks
*Status Description Units Observed Max Min Comments
Machine needs to be operating at High Idle, with the transmission shift lever in
2.3.1 Cylinder Speed Tests
the FIRST speed position and the differential unlocked.
h the transmission shift lever in theBlade
FIRSTLift
speed position and the differential unlocked.

When performing cycle times on these cylinders, place two marks 305mm apart
Rod IN 3.2 2.4
Sec on cylinder rod. This is called your "running distance".
When performing cycle times on these cylinders, place two marks 305mm apart
Rod Out 2.9 2.1
Sec on cylinder rod. This is called your "running distance".
, place two marks 305mm apart onCentershift
cylinder rod. This is called your "running distance".

When performing cycle times on these cylinders, place two marks 305mm apart
Rod IN 7.5 5.3
Sec on cylinder rod. This is called your "running distance".
When performing cycle times on these cylinders, place two marks 305mm apart
Rod Out 7.1 5.3
Sec on cylinder rod. This is called your "running distance".
, place two marks 305mm apart onWheel
cylinder rod. This is called your "running distance".
Lean
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod IN 2.3 1.7
Sec distance".
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod Out 2.3 1.7
Sec distance".
m apart on cylinder rod. This is called
Bladeyour
Tip"running distance".
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod IN 2.9 2.3
Sec distance".
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod Out 3.0 2.2
Sec distance".
m apart on cylinder rod. This is called
Sideyour "running distance".
Shift
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod IN 10.3 7.7
Sec distance".
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod Out 10.4 7.8
Sec distance".
m apart on cylinder rod. This is called your "running
Scarcifier distance".
(if equipped)
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod IN 3.4 2.6
Sec distance".
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod Out 2.3 1.7
Sec distance".
*Status Description Units Observed Max Min Comments
Comments Ripper to ground (if equipped)
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod IN 6.9 3.9
Sec distance".
Place two marks 305mm apart on cylinder rod. This is called your "running
Rod Out 4.7 3.5
Sec distance".
m apart on cylinder rod. This is called your "running distance".
Articulation
Machine needs to be operating at High Idle, with the transmission shift lever in
Rod IN 4.8 3.0
Sec the FIRST speed position and the differential unlocked.
Machine needs to be operating at High Idle, with the transmission shift lever in
Rod Out 4.8 3.0
Sec the FIRST speed position and the differential unlocked.
2.3.2 2.3.2 Cylinder Drift Tests Units Observed Oil Temperature Ranges
Oil Temperature Oil Temperature - - -
Units Observed Maximum Maximum Allowable Maximum Allowable Time Maximum Allowable
- Allowable Time (sec) (sec) Time (sec)
Movement

Blade Lift (Left Cylinder) - - - -

Blade Lift (Right Cylinder) - - - -

Wheel Lean (Left Cylinder) - - - -

Wheel Lean (Right Cylinder) - - - -

3. Hydraulic & Steering System


3.1 Steering Hydraulic System
Status Description Units Observed Specified (+)Tol (-)Tol Comments
3.1.1 3.1.1 Pump Control Valve From Testing and Adjusting Hydraulic Systems SENR9186-07.

Low Pressure Standby (High Idle) KPA 3300 689 689

True Low Pressure Standby (High Idle) KPA 2100 150 150
From Testing and Adjusting Hydraulic Systems SENR9186-07.
3.1.2 3.1.2 Steering Wheel Slip Check

Steering Pressure Against Stops - - -

Steering Wheel Revolutions from Stop to Stop 6.5 - -

3.1.3 Maxium Steering Pressure KPA 18616 689 689


3.2 Implement Hydraulic System
*Status Description Units Observed Specified (+)Tol (-)Tol Comments
3.2.1 Implement Stall Pressure KPA 24132 1034 1034
3.3 Hydraulic Fan System
*Status Description Units Observed Specified (+)Tol (-)Tol Comments
3.3.1 3.3.1 Hydraulic Fan (If Equipped)

Fan Speed (High Idle) - - -

High Pressure Cut-Off (High Idle) - - -

Fan Speed (Low Idle) - - -

Margin Pressure (Low Idle) - - -


3.3 Miscellaneous Hydraulic
*Status Description Units Observed Specified (+)Tol (-)Tol Comments
3.3.1

3.3.2

3.3.3

4. Air & Brake System


4.1 Air & Brake System
Status Description Units Observed Specified (+)Tol (-)Tol Comments
Start engine and bring air system to max pressure. Check valves, hoses, and
4.1.1 Leakage Test - - -
connecitons with soapy water for leaks.
4.1.2 4.1.2 Air Pressure Guage Test

Pressure Difference (Right to Left Tank) - - -

- Pressure Difference (Machine Gauge to Master Gauge)

Right Tank Gauge 35 - - Maximum


KPA
Left Tank Gauge 35 - - Maximum
KPA
4.1.3 4.1.3 Air Compressor Governer Test

Cut IN, Pressure KPA 790 70 70

Cut OUT, Pressure KPA 965 34 34

4.1.4 4.1.4 Indicators for Low Air Pressure Test

Cut IN, Pressure 530 - - Approximately


KPA
Cut OUT, Pressure 640 - - Approximately
KPA
4.1.5 Low Brake Air Pressure Alarm Test 530 - - Minimum
KPA
4.1.6 Low Brake Air Pressure - Indicator 530 - - Minimum
KPA
4.1.7 Stop Lamp Brake Air Pressure Switch Test 45 - - Approximately
KPA
4.2 Miscellaneous Air & Brake
*Status Description Units Observed Specified (+)Tol (-)Tol Comments
4.2.1

4.2.2

4.2.3

5. Powertrain
5.1 Transmission Pressure Tests
Status Description Units Observed Minimum Maximum Comments
5.1.1 5.1.1 Transmission Charge Pump Test

Low Idle (with Differential Lock ON) 2690 - NEUTRAL position. For 2FM1-399 2750 kPa.
KPA
High Idle (with Differential Lock ON) 3240 - NEUTRAL position. For 2FM1-399 3300 kPa.
KPA
*Status Description Units Observed Minimum Maximum Comments
5.1.2 5.1.2 Transmission Lubrication Oil Test

Neutral (Low Idle with Differential Lock ON) 28 - For 2FM1-399 80 ± 30 kPa.
KPA
Neutral (High Idle with Differential Lock ON) 345 - For 2FM1-399 558 ± 55 kPa.
KPA
Frist Gear Forward (Low Idle with Differential Lock ON)
7 -
KPA
Frist Gear Forward (High Idle with Differential Lock ON) For 2FM1-399 241 ± 27 kPa.
207 -
KPA
Transmission oil pressures that vary with the differential lock in the ON position
Neutral (Low Idle with Differential Lock OFF) 28 -
KPA indicate leakage in the differential lock system.
Transmission oil pressures that vary with the differential lock in the ON position
Neutral (High Idle with Differential Lock OFF) 345 -
KPA indicate leakage in the differential lock system.
Frist Gear Forward (Low Idle with Differential Lock Transmission oil pressures that vary with the differential lock in the ON position
7 -
OFF) KPA indicate leakage in the differential lock system.
Frist Gear Forward (High Idle with Differential Lock Transmission oil pressures that vary with the differential lock in the ON position
207 -
OFF) KPA indicate leakage in the differential lock system.
5.1.3 5.1.3 Transmission Pressure Tests

Transmission Pre (Perform Test at Low Idle with Differential Lock OFF) Units Observed Specified (+)Tol (-)Tol Comments
Clutch 1 (First Gear, Forward) 2275 to 2080 - - For 2FM1-399 2180 ± 95 kPa.
KPA
Clutch 2 (Second Gear, Forward) 2445 to 2255 - - For 2FM1-399 2350 ± 95 kPa.
KPA
Clutch 3 (First Gear, Reverse) 2365 to 2145 - - For 2FM1-399 2255 ± 110 kPa.
KPA
Clutch 4 (Second Gear, Forward) 2075 to 1855 - - For 2FM1-399 1965 ± 110 kPa.
KPA
Clutch 5 (Neutral) 2875 to 2710 - - For 2FM1-399 2790 ± 85 kPa.
KPA
Clutch 6 (First Gear, Forward or Reverse) 2760 to 2580 - - For 2FM1-399 2670 ± 90 kPa.
KPA
Clutch 7 (First, Forward or Reverse) or (Second, For 2FM1-399 1540 ± 85 kPa.
2815 to 2525 - -
Forward) KPA
Clutch 8 (Neutral) 2765 to 2570 - - For 2FM1-399 2670 ± 95 kPa.
KPA
Minimum. Move the transmission control lever to FIRST GEAR FORWARD
5.1.4 Clutch Control - Test 2125 - - position and operate at half throttle. Depress clutch pedal. The transmission
KPA should be turning.
Minimum. Remove the differential drive shaft. Operate the machine in first gear
5.1.5 Differential Lock Pressure 2620 - - forward at high idle. Engage the differential lock valve.
KPA
5.2 Miscellaneous Power Train
Status Description Units Observed Specified (+)Tol (-)Tol Comments
5.2.1

5.2.2

5.2.3

6. Electrical System
6.1 Electrical System
Status Description Units Observed Specified (+)Tol (-)Tol Comments
6.1.1 6.1.1 Battery Voltage

Engine Stopped - - -

Low Idle - - -

High Idle V 28.0 1.0 1.0


6.1.2 Inspect Battery Cables

6.1.3 Starter Draw Test 67.5 7.5 7.5 For Starter Motor Gp 207-1555 no load test.
A
6.2 Miscellaneous Electrical
*Status Description Units Observed Specified (+)Tol (-)Tol Comments
6.2.1

6.2.2

6.2.3

7. S·O·S
7.1 S·O·S Sampling
Status Description Obtain Comments
7.1.1 Engine Oil Sample

7.1.2 Engine Coolant Sample (Level II)

7.1.3 Hydraulic Oil Sample

7.1.4 Transmission Oil Sample


Blowby Tools Needed
Service Brake Holding Ability Tes
Part Part Name Quantity 1. Start the engine. Raise the blade slightly. Depress the transmi
Number

285-0910 Multi-Tool Gp 1 2. Move the transmission control (lever) to FIFTH SPEED FORW

285-0900 Blowby Tool 1 3. Gradually release the transmission modulator control. The ma
Group

NETG504 Software 1 4. Reduce the engine speed to low idle. Engage the parking brak
4 license
olding Ability Test Parking Brak
ade slightly. Depress the transmission modulator control. Apply the service brake control. 1. Position the machine

(lever) to FIFTH SPEED FORWARD. Increase the engine speed to high idle. 2. Engage the parking b
service brake control.
ssion modulator control. The machine should not move. The engine should stall.

ow idle. Engage the parking brake control. Lower the blade to the ground. Stop the engine.
Parking Brake Holding Ability Test
1. Position the machine on a slope of 20 percent.

2. Engage the parking brake control. Release the service brake control. The wheels should not rotate. If the wheels rotate, engage the
service brake control.
eels rotate, engage the