D10R TECHNICAL ANALYSIS INSPECTION LEVEL 2

MACHINE MODEL: MACHINE SERIAL NUMBER: AKT

CUSTOMER UNIT NUMBER: MACHINE SMU:

DATE INSPECTION PERFORMED: INSPECTIONS PERFORMED BY: PT.Trakindo Utama

LOCATION OF INSPECTION: CUSTOMER NAME: PT. TCI

TCI SUPERVISOR NAME TCI SUPERVISOR SINGNATURE

RESULTS
ENGINE: GOOD CONDITION FAIR CONDITION POOR CONDITION

COMMENTS:

HYDRAULIC SYSTEM: GOOD CONDITION FAIR CONDITION POOR CONDITION

COMMENTS:

TRANSMISSION: GOOD CONDITION FAIR CONDITION POOR CONDITION

COMMENTS:

STEERING CLUTCH & BRAKE: GOOD CONDITION FAIR CONDITION POOR CONDITION

COMMENTS:

GENERAL MACHINE CONDITION: GOOD CONDITION FAIR CONDITION POOR CONDITION

COMMENTS:

D10R TA2 AKT

 Version 1.0

D10R TA2 AKT

 Important Safety Information
Note: Proper repair is important to the safe operation and the reliable operation of this equipment. The following document should be
used in conjunction with the correct service manual as they outline basic recommended procedures. Some of the procedures require
special tool, devices or work methods.

Improper operation, lubrication, maintenance or repairs to this equipment can be dangerous and could result in injury or death. Please
read and understand all safety messages and information in the service manual before performing any testing or repairs.

Following are some basic points on Safety:

License Requirement: Do not operate under any circumstance unless you have the required license

Safety Signs, Cautions & Alerts: Make sure you understand safety warning, caution and alert signs.

Personal Protective Equipment: Wear the required personal safety equipment in the area you are working.

Mounting & Dismounting: Use steps, handholds, work platforms and walkways as required.

Work Area: Ensure work area is clear and has sufficient clearance to perform tests

Demarcation: Ensure that Barricades and demarcation signs are in place prior to starting the job

Isolation and Tagging: Ensure that correct Isolation and Tagging Procedure has been followed

Prior to starting any testing read and understand the following Caterpillar Reference Literature:

SENR1017 Specifications 3408E & 3412E Engines for Caterpillar Built Machines
SENR1018 System Operation and Testing and Adjusting 3408E & 3412E Engines for Caterpillar Built Machines
SENR1054 Troubleshooting 3408E & 3412E Engines for Caterpillar Built Machines
RENR3924 Specifications D10R Track Type Tractor Power Train
RENR3925 System Operation D10R Track Type Tractor Power Train
RENR3926 Testing and Adjusting D10R Track Type Tractor Power Train
RENR3695 System Operation and Testing and Adjusting D10R Track Type Tractor Power Train Electronic Control System
RENR3928 Specifications D10R Track Type Tractor Hydraulic System
RENR8155 System Operation and Testing and Adjusting D10R Track Type Tractor Hydraulic System
SENR9457 System Operation and Testing and Adjusting D10R Track Type Implement Electronic Control System
SENR9413 System Operation and Testing and Adjusting D10R Track Type Vital Information Display System (VIDS)
RENR3920 Service Manual D10R Track Type Tractor AKT 1 - Up Volume I
RENR3920 Service Manual D10R Track Type Tractor AKT 1 - Up Volume 2

D10R TA2 AKT

D10R TA2 AKT
 D10R TECHNICAL ANALYSIS INSPECTION LEVEL 2

Attention!
This TA2 inspection is for testing purposes ONLY! Testing sheets
must be completed in full before any additional task is carried out.
Faults or defects found during testing and inspection are not to be
repaired, technician will record on the TA2 inspection sheets with
comments. Completed TA2 inspections that have machine defects
will be given to the customers workshop supervisor for approval
and creation of new W/O's. No adjustment or repair is to be done
by Trakindo without customer approval and new customer W/O.
Valve adjustments are not part of the TA2 inspection, they are to be
carried out on a separate customer W/O

D10R TA2 AKT

D10R TA2 AKT
 INDUCTION SYSTEM TEST D10R AKT

1) Remove air cleaners from machine,

2) Install induction testing tools into air cleaners, adjust air pressure regulators to 10 psi
3) Check all hose clamps are installed and rubber connections for air leaks with soapy water.
4) Mark on picture any leaks found and report to workshop supervisor

Pass Fail Comments/Recommendations

Air Induction System:
OK

Refer SEPD0635 for Caterpillar procedure and tooling required

D10R TA2 AKT

D10R TA2 AKT
 VALVE CLEARANCE ADJUSTMENT D10R AKT
A separate TU and Customer W/O is required for the valve adjustment, it is not part of the
TA2 inspection. Please check with supervisor before completing task

Intake Valves
Exhaust Valves

11 9 7 5 3 1
12 10 8 6 4 2

Tolerances for Valves

Inlet +
/- 0.003 Inch ( +/- 0.08mm) Exhaust +
/- 0.004 Inch (+/- 0.10mm)

Valve Setting's Check and Adjustment Record

Actual Measurement
Specification Adjusted To
Cylinder No. before Adjusting
Intake Exhaust Intake Exhaust Intake Exhaust
0.015 Inch 0,030 Inch
Cylinder 1
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 2
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 3
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 4
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 5
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 6
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 7
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 8
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 9
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 10
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 11
(0.38mm) (0.76 mm)
0.015 Inch 0,030 Inch
Cylinder 12
(0.38mm) (0.76 mm)

D10R TA2 AKT

 ENGINE PERFORMANCE D10R AKT
PRESSURE TESTS Repairs / Recommendations
Cooling System: Pass Fail
Air Induction System: Pass Fail

Note* Engine Coolant Temp must be above 85 Degrees Celsius while testing
TEST Actual Specification Adjusted To Comments / Repairs
Low Idle Rpm 700 ± 10 Rpm
High Idle Rpm 2110 ± 10 Rpm
Stall Rpm 1646 ± 20 Rpm
Fuel Pressure Low Idle 35 Psi Min
Fuel Pressure High Idle 40 - 97 Psi
Fuel Pressure Stall 40 - 97 Psi
Boost Pressure Low Idle
Boost Pressure High Idle
Boost pressure Stall 10 ± 2 Psi
Engine Oil Pressure Low Idle Min 18 Psi
Engine Oil Pressure High Idle Max 88 Psi
Engine Oil Pressure Stall Max 88 Psi
Injection Actuation Pressure Low Idle
Injection Actuation Pressure High Idle
Injection Actuation Pressure High Idle
Crankcase Blow-By Low Idle 650 Litres Max
Crankcase Blow-By High Idle 650 Litres Max
Crankcase Blow-By Stall 650 Litres Max
Radiator Fan Speed Low Idle
Radiator Fan Speed Low Idle
Radiator Fan Speed High Idle 1150 Rpm
Radiator Fan Speed 0% Bypass
Radiator Fan Speed 100% Bypass
Temperature Radiator Top Tank
Temperature Radiator Bottom Tank
Difference in Temperature Top to Bottom 10 - 20 Celsius
Calibrate Sensors Successful
Perform Speed Timing Calibration Successful

COLOUR OF EXHAUST SMOKE: CLEAR WHITE GREY BLACK BLUE

AMOUNT OF EXHAUST SMOKE: SMALL MEDIUM EXCESSIVE

AMOUNT AND COLOUR OF SMOKE AT CLEAR WHITE GREY BLACK BLUE

ENGINE START UP: SMALL MEDIUM LARGE

ECM:

A) Diagnostic Clock: B) Total Fuel Usage:

Download Print and Attach copies:

C) Logged Events: D) Over Speed Warnings and Severity:

General Comments / Repairs / Recommendations:

D10R TA2 AKT

 HYDRAULIC SYSTEM D10R AKT
PRESSURE TEST Actual Specification Adjusted To Comments / Repairs
Accumulator Pre- Charge Pressure 450 ± 20 Psi
Pilot Relief @ HI Implement Lock out Switch ON 570 ± 25 Psi
Pilot Relief with Blade & Ripper Raised
260 ± 30 Psi
Engine Stopped and Blade control in Neutral
ATTAAC Fan Speed Low Idle
ATTAAC Fan Speed High Idle Max 4300 Rpm
Hydraulic Fan Pump Discharge Pressure (HFPD)
600 ± 25 Psi
@ Low Idle
ATTAAC Fan Pressure High Idle 975 ± 30 Psi
Blade Tilt Cyl Relief Pressure Tilt Extend 2950 ± 10 Psi
Blade Tilt Cyl Relief Pressure Tilt Retract 2950 ± 10 Psi
Blade Lift Cyl Relief Pressure Extend 2725 ± 75 Psi
Blade Lift Cyl Relief Pressure Retract 2725 ± 75 Psi
Ripper Lift Cyl Relief Pressure Extend 2725 ± 75 Psi
Ripper Lift Cyl Relief Pressure Retract 2725 ± 75 Psi
Ripper Tilt Cyl Relief Pressure Extend 2725 ± 75 Psi
Ripper Tilt Cyl Relief Pressure Retract 2725 ± 75 Psi

CYLINDER DRIFT Actual Spec. with Oil Above 66 oC Comments / Repairs

Blade Lift Cyl Extend 1.7 Minutes to Drift 38 mm
Blade Lift Cyl Retract 1.7 Minutes to Drift 38 mm
Blade Tilt Cyl Extend 1.7 Minutes to Drift 11 mm
Blade Lift Cyl Retract 1.7 Minutes to Drift 11 mm
Ripper Lift Cyl Extend 1.7 Minutes to Drift 10 mm
Ripper Lift Cyl Retract 1.7 Minutes to Drift 25 mm

CYCLE TIMES Actual Specification Comments / Repairs

Blade Lift Cyl Extend
Blade Lift Cyl From Ground to Fully Raised 6.5 Sec
Blade Tilt from Tilt Right to Tilt Left (Single Tilt) 5.1 Sec
Blade Tilt from Tilt Left to Tilt Right (Single Tilt) 4.2 Sec
Blade Tilt from Tilt Left to Tilt Right (Dual Tilt) 5.1 Sec
Blade Tilt from Tilt Left to Tilt Right (Dual Tilt) 5.1 Sec
Ripper Lift from Fully Lowered to Fully Raised 5.9 Sec
Ripper Lift from fully Raised to Fully Lowered 6.9 Sec
Ripper Tilt Cyl Extend
Ripper Tilt Cyl Retract

ECM's Hydraulic

A) Diagnostic Clock: Hours

B) Machine Control Hours

Download Print and Attach copies:

C) Logged Events:

Calibration of all Hydraulic Implements completed: Yes No

General Comments / Repairs / Recommendations:

D10R TA2 AKT

 STEERING CLUTCH AND BRAKE
Note: Transmission Oil must be at Operating Temperature and 3rd Gear must be ACTIVE

LH CLUTCH PRESSURE
Engine RPM Trans Gear Park Brake LH Brake RH Brake Both Brakes Actual Specification Adjusted To
700 Neutral On Off Off Off 338 ± 10 Psi
700 Neutral Off Off Off Off 338 ± 10 Psi
2100 Neutral Off Off Off Off 342 ± 10 Psi
2100 Neutral Off On Off Off 0 Psi
2100 Neutral Off Off On Off 342 ± 10 Psi
2100 Neutral Off Off Off On 342 ± 10 Psi
LH BRAKE PRESSURE
700 Neutral On Off Off Off 0 Psi
700 Neutral Off Off Off Off 395 ± 25
2100 Neutral Off Off Off Off 405 ± 25 Psi
2100 Neutral Off On Off Off 38 ± 25 Psi
2100 Neutral Off Off On Off 405 ± 25 Psi
2100 Neutral Off Off Off On 0 Psi

RH BRAKE PRESSURE
700 Neutral On Off Off Off 0 Psi
700 Neutral Off Off Off Off 395 ± 25 Psi
2100 Neutral Off Off Off Off 405 ± 25 Psi
2100 Neutral Off On Off Off 405 ± 25 Psi
2100 Neutral Off Off On Off 38 ± 25 Psi
2100 Neutral Off Off Off On 0 Psi
RH CLUTCH PRESSURE
700 Neutral On Off Off Off 338 ± 10 Psi
700 Neutral Off Off Off Off 338 ± 10 Psi
2100 Neutral Off Off Off Off 342 ± 10 Psi
2100 Neutral Off On Off Off 342 ± 10 Psi
2100 Neutral Off Off On Off 0 Psi
2100 Neutral Off Off Off On 342 ± 10 Psi

ECM:
A) Perform Touch Up Pressure Calibration: Yes B) Steering Clutch High Pressure Adjustment: Yes

C) Brake Low Pressure Adjustment: Yes D) Steering Clutch Low Pressure Adjustment: Yes

General Comments / Repairs / Recommendations:

* Note: After completion ensure that 3rd Gear is locked out

D10R TA2 AKT

 Note: Transmission Oil must be at Operating temperature AND 3rd Gear must be ACTIVE

TORQUE CONVERTER AND TRANS LUBE

TORQUE CONVERTER SUPPLY
Engine RPM Trans Gear Park Brake LH Brake RH Brake Both Brakes Actual Specification Adjusted To
700 Neutral On Off Off Off 44 Psi
2100 Neutral Off Off Off Off 135 ± 10 Psi
2100 Neutral Off On Off Off 135 ± 10 Psi
2100 Neutral Off Off On Off 135 ± 10 Psi
2100 Neutral Off Off Off On 135 ± 10 Psi
1650 3F Off Off Off On 105 ± 10 Psi

TORQUE CONVERTER OUTLET

700 Neutral On Off Off Off 44 Psi
2100 Neutral Off Off Off Off 80 ± 10 Psi
2100 Neutral Off On Off Off 80 ± 10 Psi
2100 Neutral Off Off On Off 80 ± 10 Psi
2100 Neutral Off Off Off On 80 ± 10 Psi
1650 3F Off Off Off On 60 ± 10 Psi

LUBE MANAGEMENT
700 Neutral On Off Off Off 2 Psi
2100 Neutral Off Off Off Off 30 ± 4 Psi
2100 Neutral Off On Off Off 30 ± 4 Psi
2100 Neutral Off Off On Off 30 ± 4 Psi
2100 Neutral Off Off Off On 30 ± 4 Psi
1650 3F Off Off Off On 18 ± 4 Psi

TRANSMISSION LUBE
700 Neutral On Off Off Off 1.5 Psi
2100 Neutral Off Off Off Off 23 ± 4 Psi
2100 Neutral Off On Off Off 23 ± 4 Psi
2100 Neutral Off Off On Off 23 ± 4 Psi
2100 Neutral Off Off Off On 23 ± 4 Psi
1650 3F Off Off Off On 13 ± 4 Psi

TRANSMISSION RELIEF
700 Neutral On Off Off Off 400 ± 20 Psi
2100 Neutral Off Off Off Off 435 ± 20 Psi
2100 Neutral Off On Off Off 435 ± 20 Psi
2100 Neutral Off Off On Off 435 ± 20 Psi
2100 Neutral Off Off Off On 435 ± 20 Psi
1650 3F Off Off Off On 426 ± 15 Psi

PRIORITY VALVE
700 Neutral On Off Off Off 65 ± 15 Psi
700 Neutral Off Off Off Off 430 ± 20 Psi
2100 Neutral Off Off Off Off 160 ± 20 Psi
2100 Neutral Off On Off Off 160 ± 20 Psi
2100 Neutral Off Off On Off 160 ± 20 Psi
2100 Neutral Off Off Off On 160 ± 20 Psi
1650 3F Off Off Off On 125 ± 20 Psi

General Comments / Repairs / Recommendations:

D10R TA2 AKT

 TRANSMISSION CLUTCH PRESSURES

Transmission Gear Clutch Number Engine Speed Actual Specification Adjusted To

LI
Neutral 3
HI 438 +/- 15 Psi

LI
2
HI 438 +/- 15 Psi
1st Forward
LI
5
HI 350 +/- 30 Psi

LI
2
HI 438 +/- 15 Psi
2nd Forward
LI
4
HI 438 +/- 15 Psi

LI
2
HI 438 +/- 15 Psi
3rd Forward
LI
3
HI 438 +/- 15 Psi

LI
1
HI 438 +/- 15 Psi
1st Reverse
LI
5
HI 350 +/- 30 Psi

LI
1
HI 438 +/- 15 Psi
2nd Reverse
LI
4
HI 438 +/- 15 Psi

LI
1
3rd Reverse HI 438 +/- 15 Psi
LI
3
HI 438 +/- 15 Psi

Replaced 8C6761 Circlip: Yes No

ECM and Electrical Calibrations:

A) Diagnostic Clock : H

B) FNR Calibration Completed: Yes C) Transmission Fill Calibration Completed: Yes

Download Print and Attach copies: Yes

D) Logged Events: E) After Download completed Clear Events where Possible: Yes

* Note: After completion ensure that 3rd Gear is locked out

General Comments / Repairs / Recommendations:

D10R TA2 AKT

LOCATION PRESSURE TAP

CLUTCH NO 5

CLUTCH NO 1

CLUTCH NO 3

CLUTCH NO 2

CLUTCH NO 4

TRANSMISSION RELIEF VALVE

N : TORQUE CONVENTER OUTLET PRESSURE TAP