- Quarry Truck:
- 775F (S/N: DLS1-UP)
Introduction
Inspections are the most basic form of condition monitoring. The 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 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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- Open the document with Microsoft Word.
Electrical System
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     | 12.4 VDC or more     |     | Refer to Special Instruction, SEHS7633, "Battery Test Procedure".     |
    | Charging System Test     | 18 VDC to 32 VDC     |     | Refer to Special Instruction, REHS0354, "Charging System Troubleshooting".     |
    | Electric Starting System Test     | 12 to 16 V at −23° C (−10° F) to −7° C (19° F)     |
    | Refer to Testing and Adjusting, SENR9937, "Electric Starting System - Test".     |
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 |
Engine
Cooling System
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Radiator Pressure Relief (Radiator Cap) (2)     | -     |     |     |
    | Freezing Point of Engine Coolant     | -     |     | Use 245-5829 Coolant/Battery Tester Gp .     |
    | Conditioner Test of Engine Coolant     | -     |     | Use 8T-5296 Coolant Conditioner Test Kit .     |
    | Belt Tension     | Auto-tension     |     |     |
    | Difference between the Upper Radiator Tank Temperature and Lower Radiator Tank Temperature     | 5° + 5° - 5° C (41° + 41° - 41°F)     |
    |     |
    | Jacket Water Inlet Temperature from Cooling System     | 94° ± 3°C (201° ± 37°F)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
( 2 ) | Test for the pressure that is listed on the cap. |
Fuel System
Status (1)     | Description     | Specification     | Actual     | Comments     |
    | Fuel Pressure at LOW IDLE     | -     |     |     |
    | Fuel Pressure at HIGH IDLE     | 772 ± 258 kPa (112 ± 37 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Lubrication System
Status (1)     | Description     | Specification     | Actual     | Comments     |
    | Engine Oil Pressure at Low Idle     | 211 + 389 - 151 kPa (31 + 56 - 22 psi)     |
    |     |
    | Engine Oil Pressure at High Idle     | 334 + 266 - 154 kPa (48 + 39 - 22 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Basic Engine
Status (1)     | Description     | Specification     | Actual     | Comments     |
    | Engine Speed at Low Idle     | 800 ± 10 rpm     |     |     |
    | Engine Speed at High Idle     | 2285 ± 40 rpm     |     |     |
    | Cylinder Cutout Test     |     |     | Cat® Electronic Technician (Cat ET) Service Tool     |
    | Engine Crankcase Pressure (Blowby)     |     |     |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Air Inlet and Exhaust System
Status (1)     | Description     | Specification     | Actual     | Comments     |
    | Torque Converter Stall Test Boost Pressure     | 111.3 kPa (16.1 psi)     |
    |     |
    | Engine Speed     | 1831 rpm     |     | The stall rpm for the torque converter without torque limiting for the 775F is 1922 ± 65 rpm.     |
    | Cylinder # 3 Exhaust Temperature (2)     |     |     |     |
    | Cylinder # 4 Exhaust Temperature (2)     |     |     |     |
    | Cylinder # 5 Exhaust Temperature (2)     |     |     |     |
    | Cylinder # 6 Exhaust Temperature (2)     |     |     |     |
    | Cylinder # 7 Exhaust Temperature (2)     |     |     |     |
    | Cylinder # 8 Exhaust Temperature (2)     |     |     |     |
    | Cylinder # 9 Exhaust Temperature (2)     |     |     |     |
    | Cylinder # 10 Exhaust Temperature (2)     |     |     |     |
    | Cylinder # 11 Exhaust Temperature (2)     |     |     |     |
    | Cylinder # 12 Exhaust Temperature (2)     |     |     |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
( 2 ) | Compare the exhaust temperature variance at each exhaust port. |
Performance Checks
Operational Checks
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Raise the Dump Body     | 15 seconds     |     |     |
    | Rear Suspension Nitrogen Charged Pin to Pin Length (2)     | 1015 mm (40 inch)     |
    |     |
    | Front Suspension Nitrogen Charged Chrome Length (2)     | 170 mm (6.69 inch)     |
    |     |
    | Toe Out Measurement     | 58.67 mm (2.31 inch)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
( 2 ) | Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" |
Hydraulic System
ReferenceRefer to Testing & Adjusting, RENR8294, "Hydraulic Systems" for more detail on the following tests.
Hoist Cylinder Performance - Test
Acceptable Cylinder Drift     | |||||
Status (1)     | Minutes     | Oil Temperature     | Cylinder Drift     | Actual     | Comments     |
    | 7.0     | 38° to 48°C (100° to 119°F)     |
6.35 mm (0.25 inch)     |
    |     |
    | 4.1     | 49° to 64°C (120° to 149°F)     |
6.35 mm (0.25 inch)     |
    |     |
    | 3.0     | 65° C (150° F)     |
6.35 mm (0.25 inch)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Relief Valve (Hoist Raise, Hoist Lower) - Test and Adjust
Status (1)     | Description     | Specification     | Actual     | Comments     |
    | High Pressure     | 18950 ± 520 kPa (2750 ± 75 psi)     |
    |     |
    | Low Pressure     | 3450 ± 350 kPa (500 ± 50 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Power Train System
ReferenceRefer to Testing & Adjusting, RENR8283, "Power Train System" for more detail on the following test.
Relief Valve (Torque Converter Outlet) Pressure - Test and Adjust
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Relief Pressure at Stall rpm of 1922 ± 65 rpm     | 310 to 517 kPa (45 to 75 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Transmission Pump Pressure (Information can be found in "Worksheet")
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Transmission Pump Pressure at LOW IDLE     | 2480 kPa (360 psi) minimum     |
    |     |
    | Transmission Pump Pressure at HIGH IDLE     | 3240 kPa (470 psi) maximum     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Lubrication Pressure (Information can be found in "Worksheet")
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Lubrication Pressure at LOW IDLE     | 10 to 69 kPa (1.5 to 10 psi)     |
    |     |
    | Lubrication Pressure at HIGH IDLE     | 138 to 241 kPa (20 to 35 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Clutch Pressure (Information can be found in "Worksheet")
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Clutch 4 Pressure at LOW IDLE     | 2100 ± 140 kPa (305 ± 20 psi)     |
    |     |
    | Clutch 1 Pressure at LOW IDLE     | 2860 ± 140 kPa (415 ± 20 psi)     |
    |     |
    | Clutch 7 Pressure at LOW IDLE     |     | ||
    | Clutch 6 Pressure at LOW IDLE     |     | ||
    | Pump Pressure at LOW IDLE     | 2480 kPa (360 psi) minimum     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Pressure Calibrations for the Transmission Clutch (Information can be found in "Worksheet")
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Clutch 1 Pressure     | 2860 ± 140 kPa (414 ± 20 psi)     |
    |     |
    | Clutch 2 Pressure     | 2140 ± 140 kPa (310 ± 20 psi)     |
    |     |
    | Clutch 3 Pressure     | 2275 ± 140 kPa (330 ± 20 psi)     |
    |     |
    | Clutch 4 Pressure     | 2100 ± 140 kPa (305 ± 20 psi)     |
    |     |
    | Clutch 5 Pressure     | 2140 ± 140 kPa (310 ± 20 psi)     |
    |     |
    | Clutch 6 Pressure     | 2860 ± 140 kPa (414 ± 20 psi)     |
    |     |
    | Clutch 7 Pressure     | 2860 ± 140 kPa (414 ± 20 psi)     |
    |     |
    | Lockup Pressure     | 2070 ± 140 kPa (300 ± 20 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Worksheet
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Torque Converter Inlet Relief Pressure     | 955 ± 95 kPa (139 ± 14 psi) maximum at high idle with cold oil     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Steering System
ReferenceRefer to Testing & Adjusting, RENR8292, "Steering System" for more detail on the following test.
Check and Relief Valve (Steering) - Test and Adjust
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Main Relief Valve Pressure for Secondary Steering     | 17580 ± 1035 kPa (2550 ± 150 psi)     |
    |     |
    | Backup Relief Valve Pressure for Secondary Steering     | 20700 ± 400 kPa (3002 ± 58 psi)     |
    |     |
    | Backup Relief Valve for the Primary Steering (2)     | 26000 ± 400 kPa (3771 ± 58 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
( 2 ) | This information can be found in "Worksheet". |
Piston Pump (Steering) Pressure - Test and Adjust
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | High Pressure Cutoff Valve Pressure     | 20685 to 22065 kPa (3000 to 3200 psi)     |
    |     |
    | Flow Compensator Valve Pressure     | 2000 to 3600 kPa (290 to 522 psi)     |
    |     |
    | Cutoff Pressure (Pressure Compensator Valve) (2)     | 21200 ± 350 kPa (3050 ± 50 psi)     |
    |     |
    | Low Pressure Standby (Pressure Compensator Valve) (2)     | 3600 kPa (520 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
( 2 ) | This information can be found in "Worksheet". |
Pressure Reducing Valve (Steering) - Test (Information can be found in "Worksheet")
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Pressure Reducing Valve Pressure     | 2600 + 500 - 200 kPa (375 + 73 - 29 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Relief Valve (Steering Cylinder) - Test (Information can be found in "Worksheet")
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Steering Cylinder Relief Valve Pressure     | 27200 ± 690 kPa (3945 ± 100 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Braking System
ReferenceRefer to Testing & Adjusting, RENR8294, "Hydraulic System" for more detail on the following test.
Service Brake Discs - Check
Table For Determining The Wear Of Friction Disc     | |
Percentage Of Disc Wear     | Disc Thickness     |
0 percent     | 5.08 mm (0.200 inch)     |
10 percent     | 5.03 mm (0.198 inch)     |
20 percent     | 4.98 mm (0.196 inch)     |
30 percent     | 4.93 mm (0.194 inch)     |
40 percent     | 4.88 mm (0.192 inch)     |
50 percent     | 4.83 mm (0.190 inch)     |
60 percent     | 4.78 mm (0.188 inch)     |
70 percent     | 4.72 mm (0.186 inch)     |
80 percent     | 4.67 mm (0.184 inch)     |
90 percent     | 4.63 mm (0.182 inch)     |
100 percent     | 4.57 mm (0.180 inch)     |
Table For Determining The Wear Of The Grooves In The Friction Disc (1)     | |
Percentage Of Disc Wear     | Disc Groove Depth     |
0 percent     | 0.64 mm (0.025 inch)     |
10 percent     | 0.62 mm (0.024 inch)     |
20 percent     | 0.60 mm (0.024 inch)     |
30 percent     | 0.59 mm (0.023 inch)     |
40 percent     | 0.57 mm (0.022 inch)     |
50 percent     | 0.55 mm (0.022 inch)     |
60 percent     | 0.53 mm (0.021 inch)     |
70 percent     | 0.51 mm (0.020 inch)     |
80 percent     | 0.50 mm (0.020 inch)     |
90 percent     | 0.48 mm (0.019 inch)     |
100 percent     | 0.46 mm (0.018 inch)     |
( 1 ) | This measurement is based on three measurements per side and the measurements are taken at 25.4 mm (1.00 inch) from the outside of the disc. |
Service Brakes and Retarder System Pressure - Test
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Oil Pressure at Rear Slack Adjuster Retarder Full ON     |
5000 ± 690 kPa (720 ± 100 psi)     |
    |     |
    | Oil Pressure at Front Brakes Retarder Full ON     |
0     |     |     |
    | Oil Pressure at Rear Slack Adjuster Retarder OFF     |
6065 ± 345 kPa (880 ± 50 psi)     |
    |     |
    | Oil Pressure at Front Brakes Retarder OFF     |
7000 ± 690 kPa (1015 ± 100 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Slack Adjuster - Test and Adjust
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Residual Pressure     | 127 kPa (18 psi)     |
    |     |
    | Force to move piston     | 220 N (50 lb)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Brake Cooling Pressure - Check
Status (1)     | Description     | Specification     | Actual     | Comments     |
---|---|---|---|---|
    | Low Idle     | 14 kPa (2 psi)     |
    |     |
    | High Idle     | 172 kPa (25 psi)     |
    |     |
( 1 ) | N = Normal, M = Monitor, A = Action |
Brake Accumulator - Test and Charge
Accumulator Precharge Pressure/Temperature Relationship for the 5500 kPa (800 psi) Brake Accumulator     |
|
Temperature     | Pressure (1)     |
−7°C (20°F)     |
5000 kPa (725 psi)     |
−1°C (30°F)     |
5105 kPa (740 psi)     |
4°C (40°F)     |
5235 kPa (760 psi)     |
10°C (50°F)     |
5340 kPa (775 psi)     |
16°C (60°F)     |
5420 kPa (785 psi)     |
21°C (70°F)     |
5500 kPa (800 psi)     |
27°C (80°F)     |
5605 kPa (815 psi)     |
32°C (90°F)     |
5735 kPa (830 psi)     |
38°C (100°F)     |
5840 kPa (845 psi)     |
43°C (110°F)     |
5920 kPa (860 psi)     |
49°C (120°F)     |
6000 kPa (875 psi)     |
( 1 ) | Nominal allowable tolerance equals ± 70 kPa (± 10 psi). |
S.O.S
ReferenceRefer to Operation and Maintenance Manual, SEBU7794, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.
Status (1)     | Description     | Obtain     | Comments     | |
---|---|---|---|---|
    | Engine Oil Sample     |     |     | |
    | Cooling System Coolant Sample (Level I)     |     |     | |
    | Cooling System Coolant Sample (Level II)     |     |     | |
    | Hoist, Torque Converter, and Brake Tank Oil Sample     |     |     | |
    | Front Wheel Oil Sample     |     |     | |
    | Differential and Final Drive Oil Sample     |     |     | |
    | Transmission Tank Oil Sample     |     |     | |
    | Steering System Oil Sample     |     |     |
( 1 ) | N = Normal, M = Monitor, A = Action |