PREVENTATIVE MAINTENANCE SCHEDULE
SERVICE TYPE: (Please Circle)
500 / 2000 / 6000 HR
MODEL: CAT 796AC
UNIT#:
DATE:
SMU:
W/O #:
LEGEND: A = Inspection completed, no defects.
[S] = Statutory
B = Inspection completed, minor defect, fix when convenient.
= Service / Check not required
C = Defect recorded, requires immediate repair - report to supervisor immediately.
ALL PERSONS WORKING ON SERVICE MUST PLACE THEIR NAME,
THE DATE AND HOW MANY HOURS THEY SPENT ON THE LUBE
SERVICE AND / OR THE MECHANICAL INSPECTION IN THE
APPROPRIATE SPACE BELOW. (TIME SPENT ON DEFECT REPAIRS
IS NOT TO BE RECORDED IN THIS AREA).
INSERT LABOUR
HOURS
TARGET TOTAL LABOUR HRS TO
COMPLETE SERVICE
500 HR
NAME
DATE
ELECTRICAL SERVICE
8 Hours
2 x HV - 16 hrs
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
NAME
DATE
ELECTRICAL SERVICE
TRADE HRS
2000 HR
6000 HR
10 Hours
12 Hours
2 x HV - 20 hrs 2 x HV - 24 hrs
PRIOR TO COMMENCING THIS SERVICE ENSURE ISOLATION PROCEDURES ARE FOLLOWED.
ENSURE CORRECT PROCEDURES ARE FOLLOWED WHEN ACCESSING ELECTRICAL CABINETS AND WORKING ON OR
NEAR HV CONDUCTORS.
DC POWER BUS VOLTAGE OF 50 VDC OR LESS MUST BE MANUALLY MEASURED AND CONFIRMED IN THE INVERTER DYNAMIC
RETARDING CONTACTOR COMPARTMENT BEFORE ANY ENCLOSURE COVERS CAN BE ACCESSED.
PERSON / PERSONS COMPLETING SPECIFIC TASKS MUST INITIAL EACH TASK / CHECK WHEN COMPLETED. PLACE YOUR
INITIALS IN THE CURRENT SERVICE INTERVAL COLUMN.
Page 1
1.00 PRE SERVICE RUNNING CHECKS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
Check the blower motor by listening for unusual noises, particularly
the motor bearings.
Check that both inverter active indicator lamps are operational.
1.02
Note: Lamps illuminate when voltage is over 150.0 VDC.
Carry out DC ground fault test. Note: Refer to page 6 for
1.03
procedure
1.01
!
PRIOR TO COMMENCING THIS SERVICE ENSURE ISOLATION PROCEDURES ARE FOLLOWED
2.00 ISOLATOR BOX & EMERGENCY STOPS
2.01
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
Check cables, circuit breakers, relays in the isolator box for signs of
damage and that connections are tight.
2.02 Check isolator box latches and seals.
[S] Inspect the condition of wiring, connections and seals in the
2.03 ground level emergency stop enclosure. Clean and repair as
required.
3.00 TOP DECK ELECTRICAL BOX
3.01 Vacuum inside of the Electrical Box.
Check cables, circuit breakers, relays in the electrical box for signs
of damage and that connections are tight.
Check electrical box for loose seals, missing hardware / fasteners,
3.03
dents, contamination. Replace if damaged.
3.02
3.04 Check that all ECM's are secure and dust free.
4.00 CABIN
4.01 Clean the cabin and all compartments thoroughly.
4.02
Check electrical enclosures for loose seals, missing hardware /
fasteners, dents, contamination. Replace if damaged.
4.03 Check connections inside dash compartment.
4.04 Check shift selector moves freely.
4.05 Check that the dump body hoist lever is not loose and does not.
4.06 Check all covers for clip / screw condition, replace if missing.
4.07
Check cables / relays in the cabin for signs of damage and that
connections are tight.
4.08 Check cabin circuit breakers for system working correctly.
5.00 RETARDING GRID
Check electric retarder condition. Use a bristle brush or vacuum
cleaner to remove dirt / debris from inlet screen.
Check electric harness cabling around electric retarder for signs of
5.02
wear and contamination, replace if damaged.
Check electric harness hangers / spacers around electric retarder
5.03
for signs of wear, replace if damaged or missing.
Check grid hardware / mounts are secure and look for signs of
5.04
excessive vibration.
5.01
6.00 MACHINE WIRING
Check electric harness cabling through chassis for signs of wear
and contamination, replace if damaged.
Check electric harness hangers / spacers through chassis for signs
6.02
of wear, replace if damaged or missing.
Check ground studs condition, replace if damaged.
6.03
Note: Refer to section 15 for locations.
6.01
7.00 INVERTER CABINET (EXTERIOR)
7.01
Check the inverter enclosure and air intake for foreign objects and
signs of electrical tracking or arcing.
Page 2
!
7.00 INVERTER CABINET (EXTERIOR)
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
7.02 Clean exterior of inverter cabinet with vacuum or brush.
Check electrical cabinet back mounting bolts for security and
integrity.
Check cabinet door front and rear seals are in place and in good
7.04
condition.
7.03
7.05 Check that all latches work and are in good condition.
Change inverter cabinet enclosure air filters.
(7 x 313-4082)
Check all cables entering the cabinets are secure and glands are
7.07
tight. Remove plugs to inspect external connections.
7.06
8.00 INVERTER CABINET (INTERIOR)
8.01 Vacuum inside the front and rear cabinet compartments.
8.02
8.03
8.04
8.05
8.06
Check inverter cabinet enclosure for loose seals, missing hardware
/ fasteners, dents, contamination. Replace if damaged.
Change inverter cabinet pressurizing filter (ensure air filter
compartment is vacuumed before fitting new filter).
(1 x 201-5023)
Check retarding contact tips for excessive wear, heat or pitting.
Note: If tips have worn into the base, then both of the movable
and stationary contact tips must be replaced.
Change retarding contactor tips.
(2 x 330-3994)
Check arc chutes for bent / melted / missing metal components,
loose / missing magnets and damage from excessive heat or
severe melting.
Check the electrical and fibre optic wiring inside the inverter cabinet
8.07 and verify connections are secure. Check for hot / loose
connections at plugs, terminals, etc.
9.00 GENERATOR
Clean generator sensor covers and ensure seals are in place and
in good condition.
Check temperature sensors integrity and for loose
Bearing
hardware / connections, worn insulation, corrosion.
9.02
Replace if damaged.
Winding
Note: Ensure plugs / connections are clean.
9.01
Check both stator leads for loose hardware, worn
9.03 insulation, corrosion and security. Replace if
damaged.
Exciter
Main
9.04 Clean generator outlet screen panel from contamination.
Clean coupler adapter cover with a bristle brush or vacuum to
remove contamination.
Megohmmeter test the stator insulation resistance for
Exciter
the generator. Record results.
9.06
Note: Notify supervisor if reading is below 3.0MΩ.
Main
Ref: UENR2267-09 for procedure.
9.05
Exciter Stator Resistance…................MΩ
Main Stator Resistance……................MΩ
9.07 Check exciter armature and rotating rectifier condition.
9.08
Lubricate power generator bearings 70 Grams to ea grease point
Note: Use CAT 454-0291 high speed ball bearing grease.
9.09 Inspect generator bearing permalubes, if fitted.
10.00 ELECTRIC DRIVE COOLING FAN
500
Check speed sensor integrity and for loose hardware / connections,
10.01 worn insulation, corrosion. Replace if damaged.
Note: Ensure plugs / connections are clean.
10.02 Check blower motor ducting and clamps for damage and security.
Page 3
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
10.00 ELECTRIC DRIVE COOLING FAN
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
Inspect the blower wheel for signs of cracking and excessive wear.
Ensure they are not rubbing against the inlet ducting and check
10.03 there are no signs of excessive vibration. Roll the blower wheel by
hand and listen for unusual noises, especially in the area of the
motor bearings.
Lubricate the blower fan adapter bearings.
Note: Use CAT 454-0291 high speed ball bearing grease.
10.04
A: 57 Grams
B: 15 Grams
11.00 WHEEL MOTORS
Inspect both junction boxes for damage and ensure seals on the
covers are in place.
Check temperature sensors integrity and for loose
LH
hardware / connections, worn insulation, corrosion.
11.02
Replace if damaged.
RH
Note: Ensure plugs / connections are clean.
Check speed sensors integrity and for loose
LH
hardware / connections, worn insulation, corrosion.
11.03
Replace if damaged.
RH
Note: Ensure plugs / connections are clean.
Check stator leads for loose hardware, worn insulation, corrosion,
11.04
contamination. Replace if damaged.
11.01
11.05 Clean rear axle outlet screen panel from contamination.
Megohmmeter test the stator insulation resistance for
LH
the traction motor. Record results.
11.06
Note: Notify supervisor if reading is below 3.0MΩ.
RH
Ref: UENR2267-09 for procedure.
Check the traction motor to rear axle ground straps condition,
11.07
replace if damaged / worn.
Lubricate traction motor bearings 70 Grams to ea grease point
11.08
Note: Use CAT 454-0291 high speed ball bearing grease.
LH Stator Resistance….......................MΩ
RH Stator Resistance…...................…MΩ
11.09 Inspect traction motor bearing permalubes, if fitted.
12.00 END OF SERVICE JOBS
500
2000
6000 A,B,C
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
12.01 Re-check that fasteners on inverter cabinet doors are engaged.
Re-check the inverter enclosure and air intake for foreign objects
and signs of electrical tracking or arcing.
Re-check that all rags & rubbish have been removed from HV
12.03
compartments.
LIST NEW AND ADDITIONAL WORK ORDERS / DEFECTS FOUND OR COMPLETED. RECORD WORK ORDER Nº & PARTS
REQUIRED.
12.02
DESCRIPTION
WORK ORDER Nº
Page 4
LIST NEW AND ADDITIONAL WORK ORDERS / DEFECTS FOUND OR COMPLETED. RECORD WORK ORDER Nº & PARTS
REQUIRED.
DESCRIPTION
WORK ORDER Nº
13.00 SERVICEMAN CLOSE OFF
COMPLETE
13.01 All tasks signed off as completed?
Yes
No
13.02 HV Permits completed / closed?
Yes
No
13.03 Work area clean, tooling returned to store and isolation tags removed?
Yes
No
!
COMPLETE
All statutory compliance [S] inspections have been completed and rectified
where required?
Yes
No
14.02 All measurements and readings are within specifications?
Yes
No
14.03 All safety related defects have been repaired?
Yes
No
!
!
ALL DEFECTS MUST BE REPORTED IMMEDIATELY TO YOUR SUPERVISOR.
14.00 SUPERVISOR SIGN OFF
14.01
DEFECT DESCRIPTION, PARTS
REQUIRED & COMMENTS
COMMENTS
EQUIPMENT IS NOT TO RETURN TO WORK UNTIL THE SUPERVISOR SECTION IS FULLY SIGNED OFF.
Supervisor Name:
Signature:
Page 5
!
1. Prepare the machine for maintenance. Shut down and discharge the high voltage electrical system. Refer to Operation and Maintenance
Manual, "Prepare the Machine for Maintenance".
2. Open cover (1) for the retarding contactor compartment on the inverter cabinet.
3. Attach an insulated jumper wire FROM ground boss (2) TO EITHER DC positive bus bar (3) OR DC negative bus bar (4).
4. Close the cover for the retarding contactor compartment.
5. Deactivate the engine lockout control. refer to Operation and Maintenance Manual, "Engine Lockout Control" for more information.
6. Start the engine and allow the voltage for the DC power bus to climb above 500V.
Note: The voltage for the DC power bus can be monitored on the Advisor screen or through ET.
7. Verify that a warning category 1 ground fault event is activated. The message "DC Ground Fault" will be displayed on the Advisor screen or
through ET.
Note: The message "DC Ground Fault" will take approximately 10 seconds to appear on the Advisor screen.
8. If a warning category 1 ground fault event does not activate, troubleshoot the ground fault procedure. For more information, refer to System
Operation, Troubleshooting, Testing & Adjusting, KENR8588 or contact your Caterpillar dealer.
9. Stop the engine.
10. Perform the drive train electrical system shutdown procedure.
11. Open the cover for the retarding contactor compartment.
12. Remove the jumper wire and securely close the access door.
13. Close the cover for the retarding contactor compartment.
Page 6
15.00 ELECTRICAL GROUND STUD CHECKS
Generator to rear engine mount
Right rear engine mount to frame rail
Rear axle box to frame
Electrical cabinet to platform
Hydraulic cabinet to platform
Comments:
Platform to frame
Inverter cabinet to platform
Retarder grid to platform
Comments:
Page 7
15.00 ELECTRICAL GROUND STUD CHECKS
Left side cooler to frame and cooler mount to
frame
Left side electrical junction boxes to frame
Right side electrical junction box to frame
Comments:
Wheel motor to rear axle box
Cab to platform
Comments:
PARTS LIST
16.00
500HR SERVICE
Qty.
PART NUMBER
Inverter Cabinet Air Pressuriser Filter Element
1
201-5023
High Speed Ball Bearing Grease
1
454-0291
Qty.
PART NUMBER
Inverter Cabinet Enclosure Air Filter
7
313-4082
Retarding Contactor Tip
2
330-3994
Qty.
PART NUMBER
Temperature Sensor (Enclosure)
2
134-2252
Speed Sensor (Output)
Speed Sensor (Traction Motor)
1
2
186-0131
264-0148
2000HR SERVICE
MISCELLANEOUS PARTS LIST
Page 8
ALTERNATIVE / ASSOCIATED
PARTS
ALTERNATIVE / ASSOCIATED
PARTS
ALTERNATIVE / ASSOCIATED
PARTS