- Off-Highway Truck/Tractor
- 773D (S/N: NBJ1-UP)
- Quarry Truck
- 775D (S/N: 8AS1-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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Electrical System
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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). |
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Battery Test |
12.4 VDC or more |
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Refer to Special Instruction, SEHS7633, "Battery Test Procedure". |
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Charging System Test |
18 VDC to 32 VDC |
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Refer to Special Instruction, REHS0354, "Charging System Troubleshooting". |
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Electric Starting System Test |
12 to 16 V at −23° C (−10° F) to −7° C (19° F) |
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Refer to Testing and Adjusting, SENR1018, "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) |
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(1) |
N = Normal, M = Monitor, A = Action |
Engine
Cooling System
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Table 2
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Radiator Pressure Relief (Radiator Cap)(2) |
- |
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Freezing Point of Engine Coolant |
- |
|
Use 245-5829 Coolant/Battery Tester Gp. |
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Conditioner Test of Engine Coolant |
- |
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Use 8T-5296 Coolant Conditioner Test Kit. |
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Belt Tension |
Auto-tension |
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For fan drive. Alternator and air conditioner belts should deflect 13 to 19 mm (0.5 to 0.7 inch). |
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Difference between the Upper Radiator Tank Temperature and Lower Radiator Tank Temperature |
5° + 5° - 5° C (41° + 41° - 41°F) |
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Jacket Water Inlet Temperature from Cooling System |
89° ± 3°C (192° ± 37°F) |
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(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Test for the pressure that is listed on the cap. |
Fuel System
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Table 3
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Fuel Pressure at LOW IDLE |
- |
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Fuel Pressure at HIGH IDLE |
564 + 174 - 196 kPa (82 + 25 - 28 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Lubrication System
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Table 4
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Engine Oil Pressure at Low Idle |
144 + 456 - 44 kPa (21 + 66 - 6 psi) |
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Engine Oil Pressure at High Idle |
345 + 255 - 70 kPa (50 + 37 - 10 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Basic Engine
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Table 5
Status(1) |
Description |
Specification |
Actual |
Comments |
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Engine Speed at Low Idle |
650 ± 10 rpm |
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Engine Speed at High Idle |
2285 ± 10 rpm |
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Cylinder Cutout Test |
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Cat® Electronic Technician (Cat ET) Service Tool |
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Engine Crankcase Pressure (Blowby) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Air Inlet and Exhaust System
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Table 6
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Stall Test Boost Pressure |
72.6 ± 10.9 kPa (10.5 ± 1.6 psi) |
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|
Engine Speed |
1832 rpm |
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Cylinder # 3 Exhaust Temperature(2) |
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Cylinder # 4 Exhaust Temperature(2) |
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Cylinder # 5 Exhaust Temperature(2) |
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Cylinder # 6 Exhaust Temperature(2) |
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Cylinder # 7 Exhaust Temperature(2) |
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Cylinder # 8 Exhaust Temperature(2) |
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Cylinder # 9 Exhaust Temperature(2) |
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Cylinder # 10 Exhaust Temperature(2) |
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Cylinder # 11 Exhaust Temperature(2) |
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Cylinder # 12 Exhaust Temperature(2) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Compare the exhaust temperature variance at each exhaust port. |
Performance Checks
Operational Checks
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Table 7
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Raise the Dump Body |
11 seconds |
|
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|
Rear Suspension Nitrogen Charged Pin to Pin Length(2) |
1015 mm (40 inch) |
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Front Suspension Nitrogen Charged Chrome Length(2) |
170 mm (6.69 inch) |
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Toe Out Measurement |
58.7 mm (2.31 inch) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks". |
Hydraulic System
Reference: Refer to Testing & Adjusting, SENR1582, "Hydraulic System" and Testing & Adjusting, RENR8419, "Hydraulic System" for more detail on the following tests.
Hoist Cylinder Performance - Test
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Table 8
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 (0.250 inch) |
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|
4.1 |
49° to 64°C (120° to 149°F) |
6.35 mm (0.250 inch) |
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3.0 |
65° C (150° F) |
6.35 mm (0.250 inch) |
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Hoist Dual Stage) - Test and Adjust
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Table 9
Status(1) |
Description |
Specification |
Actual |
Comments |
|
High Pressure |
18950 ± 520 kPa (2750 ± 75 psi)(2) |
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|
17230 ± 520 kPa (2500 ± 75 psi)(3) |
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Low Pressure |
3450 ± 350 kPa (500 ± 50 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
For S/N:8AS1-UP machines. |
(3) |
For S/N:NBJ1-UP machines. |
Relief Valve (Rear Brake Oil Cooler) - Test and Adjust
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Table 10
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Valve Pressure |
586 ± 14 kPa (85 ± 2 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Power Train System
Reference: Refer to Testing & Adjusting, SENR1573, "Power Train System" and Testing & Adjusting, RENR8407, "Power Train System" for more detail on the following tests.
Relief Valve (Torque Converter Outlet) Pressure - Test and Adjust
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Table 11
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Vale Pressure at Engine Speed of 1832 RPM |
414 ± 34 kPa (60 ± 5 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Torque Converter Inlet) Pressure - Test and Adjust
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Table 12
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Valve Pressure at HIGH IDLE |
Less than 955 ± 95 kPa (139 ± 14 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Torque Converter Lockup Clutch Supply Pressure - Test
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Table 13
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Lockup Clutch Supply Pressure at LOW IDLE |
2790 ± 35 kPa (405 ± 5 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Torque Converter Lockup Clutch Pilot Pressure - Test and Adjust
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Table 14
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Lockup Clutch Pilot Pressure at LOW IDLE |
1725 ± 70 kPa (250 ± 10 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Torque Converter Lockup Clutch Leakage - Test
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Table 15
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Maximum flow rate |
3.8 L/min (1 US gpm) |
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(1) |
N = Normal, M = Monitor, A = Action |
Torque Converter Lockup Clutch Maximum Pressure - Test
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Table 16
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Lockup Clutch Maximum Pressure at LOW IDLE |
1720 ± 70 kPa (249 ± 10 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Torque Converter Lockup Clutch Primary Pressure - Test and Adjust
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Table 17
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Lockup Clutch Primary Pressure at LOW IDLE |
960 ± 35 kPa (139 ± 5 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Gear Pump (Power Train Charging) Pressure - Test and Adjust
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Table 18
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Gear Pump Pressure at LOW IDLE |
2480 kPa (360 psi) minimum |
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Gear Pump Pressure at HIGH IDLE |
3445 kPa (500 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust
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Table 19
Primary Clutch Pressure |
Station(1) |
"A" |
"B" |
"C" |
"E" |
"F" |
"G" |
"H" |
Clutch |
No. 2 |
No. 1 |
No. 7 |
No. 5 |
No. 4 |
No. 6 |
No. 3 |
Speed Position |
Engaged Clutches |
Pressure |
Pressure |
Pressure |
Pressure |
Pressure |
Pressure |
Pressure |
NEUTRAL |
4 |
|
|
|
|
300 ± 20 kPa (44 ± 3 psi) |
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REVERSE |
1 and 7 |
|
315 ± 20 kPa (46 ± 3 psi) |
315 ± 20 kPa (46 ± 3 psi) |
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FIRST |
1 and 6 |
|
315 ± 20 kPa (46 ± 3 psi) |
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|
315 ± 20 kPa (46 ± 3 psi) |
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SECOND |
3 and 6 |
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|
315 ± 20 kPa (46 ± 3 psi) |
330 ± 20 kPa (48 ± 3 psi) |
THIRD |
2 and 6 |
440 ± 20 kPa (64 ± 3 psi) |
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|
315 ± 20 kPa (46 ± 3 psi) |
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FOURTH |
3 and 5 |
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|
310 ± 20 kPa (45 ± 3 psi) |
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|
330 ± 20 kPa (48 ± 3 psi) |
FIFTH |
2 and 5 |
440 ± 20 kPa (64 ± 3 psi) |
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310 ± 20 kPa (45 ± 3 psi) |
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SIXTH |
3 and 4 |
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|
300 ± 20 kPa (44 ± 3 psi) |
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330 ± 20 kPa (48 ± 3 psi) |
SEVENTH |
2 and 4 |
440 ± 20 kPa (64 ± 3 psi) |
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300 ± 20 kPa (44 ± 3 psi) |
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(1) |
Station "D" is not used. |
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Table 20
Specifications And Identification Of The Components Of The Pressure Control Valve |
Location of the Load Piston Body(1) |
A |
B |
C |
E |
F |
G |
H |
Thickness of the Load Piston Orifice |
4.58 mm (0.180 inch) |
4.58 mm (0.180 inch) |
6.60 mm (0.260 inch) |
2.54 mm (0.100 inch) |
4.58 inch (0.180 inch) |
6.60 mm (0.260 inch) |
4.58 mm (0.180 inch) |
Color of the Outer Spring of the Load Piston |
Light blue color |
Light green color |
Light green color |
Light blue color |
Light blue color |
Light green color |
Yellow color |
Color of the Inner Spring of the Load Piston |
Light green color |
Light blue color |
Light blue color |
Light blue color |
Light blue color |
Light blue color |
Light blue color |
Size of the Decay Orifice |
1.57 mm (0.062 inch) |
1.57 mm (0.062 inch) |
1.40 mm (0.055 inch) |
1.57 mm (0.062 inch) |
1.57 mm (0.062 inch) |
1.57 mm (0.062 inch) |
1.57 mm (0.062 inch) |
Color of the Decay Orifice |
Green color |
Green color |
Yellow color |
Green color |
Green color |
Green color |
Green color |
Show/hide table
(1) |
The location of the load piston body is identical to the location of the station for the valve. Station "D" is not used. |
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Table 21
Shims For The Pressure Control Valve
Pressure Change Per Shim |
Station(1) |
A |
B |
C |
E |
F |
G |
H |
Engaged
Clutch |
2 |
1 |
7 |
5 |
4 |
6 |
3 |
Thickness of Shim |
Pressure Change |
Pressure Change |
Pressure Change |
Pressure Change |
Pressure Change |
Pressure Change |
Pressure Change |
5J-2721 Shim |
0.13 mm (0.005 inch) |
14 kPa (2.0 psi) |
20 kPa (2.9 psi) |
20 kPa (2.9 psi) |
15 kPa (2.2 psi) |
15 kPa (2.2 psi) |
20 kPa (2.9 psi) |
17 kPa (2.5 psi) |
6J-3993 Shim |
0.25 mm (0.010 inch) |
28 kPa (4.1 psi) |
41 kPa (5.9 psi) |
41 kPa (5.9 psi) |
30 kPa (4.4 psi) |
30 kPa (4.4 psi) |
41 kPa (5.9 psi) |
33 kPa (4.8 psi) |
4M-1751 Spacer |
0.41 mm (0.016 inch) |
45 kPa (6.5 psi) |
65 kPa (9.4 psi) |
65 kPa (9.4 psi) |
48 kPa (7.0 psi) |
48 kPa (7.0 psi) |
65 kPa (9.4 psi) |
53 kPa (7.7 psi) |
5J-1036 Shim |
0.80 mm (0.031 inch) |
87 kPa (12.6 psi) |
125 kPa (18.2 psi) |
125 kPa (18.2 psi) |
92 kPa (13.3 psi) |
92 kPa (13.3 psi) |
125 kPa (18.2 psi) |
103 kPa (14.9 psi) |
Show/hide table
(1) |
Station "D" is not used. |
Transmission Hydraulic Control Clutch Pressure - Test
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Table 22
Clutch Pressure |
Station(1) |
"A" |
"B" |
"C" |
"E" |
"F" |
"G" |
"H" |
Clutch |
No. 2 |
No. 1 |
No. 7 |
No. 5 |
No. 4 |
No. 6 |
No. 3 |
Speed Position |
Engaged Clutches |
Pressure |
Pressure |
Pressure |
Pressure |
Pressure |
Pressure |
Pressure |
NEUTRAL |
4 |
|
|
|
|
2240 ± 125 kPa (325 ± 18 psi) |
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|
REVERSE |
1 and 7 |
|
2940 ± 165 kPa (426 ± 24 psi) |
2940 ± 165 kPa (426 ± 24 psi) |
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|
FIRST |
1 and 6 |
|
2940 ± 165 kPa (426 ± 24 psi) |
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|
2940 ± 165 kPa (426 ± 24 psi) |
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SECOND |
3 and 6 |
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|
|
2940 ± 165 kPa (426 ± 24 psi) |
2480 ± 140 kPa (360 ± 20 psi) |
THIRD |
2 and 6 |
2265 ± 115 kPa (329 ± 17 psi) |
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|
2940 ± 165 kPa (426 ± 24 psi) |
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FOURTH |
3 and 5 |
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|
2250 ± 125 kPa (326 ± 18 psi) |
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|
2480 ± 140 kPa (360 ± 20 psi) |
FIFTH |
2 and 5 |
2265 ± 115 kPa (329 ± 17 psi) |
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|
2250 ± 125 kPa (326 ± 18 psi) |
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SIXTH |
3 and 4 |
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|
2240 ± 125 kPa (325 ± 18 psi) |
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2480 ± 140 kPa (360 ± 20 psi) |
SEVENTH |
2 and 4 |
2265 ± 115 kPa (329 ± 17 psi) |
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|
|
2240 ± 125 kPa (325 ± 18 psi) |
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|
Show/hide table
(1) |
Station "D" is not used. |
Transmission Hydraulic Control Pilot Pressure - Test and Adjust
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Table 23
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Transmission Hydraulic Control Pilot Pressure |
1755 ± 35 kPa (255 ± 5 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Steering System
Reference: Refer to Testing & Adjusting, SENR1576, "Steering System" and Testing & Adjusting, RENR8416, "Steering System" for more detail on the following tests.
Relief Valve (Primary Steering Backup) - Test and Adjust
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Table 24
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Back up Relief Valve Pressure for the Primary Steering at LOW IDLE |
26000 ± 400 kPa (3771 ± 58 psi) |
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|
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(1) |
N = Normal, M = Monitor, A = Action |
Piston Pump (Steering) Pressure - Test and Adjust
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Table 25
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Cutoff Pressure (Pressure Compensator Valve) |
23500 ± 350 kPa (3410 ± 50 psi) |
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|
|
Low Pressure Standby (Pressure Compensator Valve) |
3170 to 4800 kPa (460 to 695 psi) |
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|
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Secondary Steering Backup) - Test and Adjust
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Table 26
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Secondary Steering Backup Relief Valve Pressure |
17300 ± 300 kPa (2510 ± 45 psi) |
|
|
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Secondary Steering Main) - Test and Adjust
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Table 27
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Secondary Steering Main Relief Valve Pressure |
15150 ± 300 kPa (2200 ± 45 psi) |
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|
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(1) |
N = Normal, M = Monitor, A = Action |
Pressure Reducing Valve (Steering) - Test
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Table 28
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Pressure Reducing Valve Pressure |
2600 + 500 - 200 kPa (377 + 75 - 30 psi) |
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|
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Steering Cylinder) - Test
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Table 29
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Steering Cylinder Relief Valve Pressure |
27200 kPa (3945 psi) |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Braking System
Reference: Refer to Testing & Adjusting, SENR1578, "Air System and Brakes" and Testing & Adjusting, RENR8410, "Air System and Brakes" for more detail on the following test.
Service Brake Discs - Check
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Table 30
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) |
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Table 31
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) |
Show/hide table
(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 for S/N:8AS1-UP machines
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Table 32
Status(1) |
Description |
Specification |
Actual |
Comments |
Retarder Control Lever Full ON |
Retarder Control Lever Full OFF |
|
|
|
Oil Pressure at Rear Slack Adjuster |
3650 kPa (530 psi) |
4345 to 5445 kPa (630 to 790 psi) |
|
|
|
Oil Pressure at Front Brakes |
0 |
15065 to 19030 kPa (2185 to 2760 psi) |
|
|
|
Air Pressure at Rear Brake Master Cylinder |
550 kPa (80 psi) |
655 to 827 kPa (95 to 120 psi) |
|
|
|
Air Pressure at Front Brake Master Cylinder |
0 |
655 to 827 kPa (95 to 120 psi) |
|
|
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(1) |
N = Normal, M = Monitor, A = Action |
Slack Adjuster - Test and Adjust
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Table 33
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Residual Pressure |
0 to 127 kPa (0 to 18 psi) |
|
|
|
Force to move piston |
220 N (50 lb) |
|
|
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(1) |
N = Normal, M = Monitor, A = Action |
Brake Cooling Pressure - Check
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Table 34
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Low Idle |
14 kPa (2 psi) |
|
|
|
High Idle |
172 kPa (25 psi) |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
S.O.S
Reference: Refer to Operation and Maintenance Manual, SEBU7093, "Maintenance Interval Schedule" and Operation and Maintenance Manual, SEBU8307, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.
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Table 35
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 |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |