- Motor Grader
- 120K (S/N: SZN1-UP)
Introduction
Inspections are the most basic form of condition monitoring. 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 effectively 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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- Click format to print.
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Electrical System
Show/hide table
Table 1
Status(1) |
Description |
Specification |
Actual |
Comments |
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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 |
12.45 VDC or more |
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Refer to Testing and Adjusting, SENR9939, "Battery - Test". |
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Charging System Test |
28 ± 1 V |
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Refer to Testing and Adjusting, SENR9939, "Charging System - Test". |
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Electric Starting System Test |
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Refer to Testing and Adjusting, SENR9939, "Electric Starting System - Test". |
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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 |
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Radiator Pressure Relief (Radiator Cap)(2) |
- |
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Use 9S-8140 Pressurizing Pump to test the radiator pressure cap. 20 kPa (3 psi) more than the pressure marked on the cap. |
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Freezing Point of Engine Coolant |
- |
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Use 245-5829 Coolant/Battery Tester Gp. |
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Conditioner Test of Engine Coolant |
- |
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Use 245-5829 Coolant Conditioner Test Kit. |
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Belt Tension |
534 ± 111 N (120 ± 25 lb) for new belts
400 ± 22 N (90 ± 5 lb) for used belts |
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Auto- Adjust Belt Tensioner |
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Upper Radiator Tank Temperature and Lower Radiator Tank Temperature |
6° to 11° C (43° to 52° F) |
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Lower Radiator Tank Temperature |
8° to 22° C (46 ° to 72 ° F) |
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Jacket Water Inlet Temperature from Cooling System |
- |
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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 |
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Fuel Pressure at LOW IDLE |
400 to 435 kPa (58 to 63 psi) |
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Fuel Pressure at normal Load condition |
400 to 525 kPa (58 to 76 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Lubrication System
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Table 4
Status(1) |
Description |
Specification |
Actual |
Comments |
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Engine Oil Pressure at LOW IDLE |
275 kPa (40 psi) |
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Engine Oil Pressure at HIGH IDLE |
600 kPa (87 psi) |
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(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 |
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Engine Speed at HIGH IDLE |
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Cylinder Cutout Test |
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Engine Crankcase Blowby Pressure |
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(1) |
N = Normal, M = Monitor, A = Action |
Air Inlet and Exhaust System
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Table 6
Status(1) |
Description |
Specification |
Actual |
Comments |
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Boost Pressure Test |
96 kPa (14 psi) |
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Cylinder # 1 Exhaust Temperature(2) |
- |
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Cylinder # 2 Exhaust Temperature(2) |
- |
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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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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Compare the exhaust temperature variance at each exhaust port. |
Performance Checks
Brake Performance Checks
Reference: Refer to Operation and Maintenance Manual, KENR8415, "Braking System - Test" for more detail on the following test.
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Table 7
Status(1) |
Description |
Perform |
Comments |
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Service Brake Test |
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Parking Brake Test |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Hydraulic Performance Checks
Reference: Refer to Testing and Adjusting, KENR8413, "Hydraulic and Steering System" for more detail on the following tests.
Cylinder Cycle Time - Check
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Table 8
Status(1) |
Description |
Specification |
Actual |
Comments |
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Blade Lift - Rod In(2) |
2.9 ± 0.4 |
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Blade Lift - Rod Out(2) |
2.9 ± 0.4 |
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Centershift - Rod In(2) |
6.6 ± 1.1 |
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Centershift - Rod Out(2) |
6.3 ± 0.9 |
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Wheel Lean - Rod In(2) |
2.0 ± 0.3 |
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Wheel Lean - Rod Out(2) |
2.0 ± 0.3 |
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Blade Tip - Rod In(2) |
2.7 ± 0.4 |
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Blade Tip - Rod Out(2) |
2.7 ± 0.4 |
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Side Shift - Rod In(2) |
9.2 ± 1.4 |
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Side Shift - Rod Out(2) |
9.3 ± 1.3 |
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Scarifier - Rod In (if equipped)(2) |
4.2 ± 0.6 |
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Scarifier - Rod Out (if equipped)(2) |
2.8 ± 0.4 |
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Ripper (If Equipped) - Rod In(2) |
6.3 ± 0.9 |
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Ripper (If Equipped) - Rod Out(2) |
4.8 ± 0.7 |
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Articulation - Rod In(3) |
4.0 ± 0.5 |
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Articulation - Rod Out |
4.0 ± 0.5 |
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Blade Circle - 1/4 rotation |
12.2 ± 1.5 |
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Steering Wheel - Number of Turns |
6 to 7 |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Cycle times are for a "running distance" of 305 mm (12 inch). |
(3) |
When you check the cycle times for these cylinders, operate the machine at high idle and place the transmission control (lever) in the FIRST SPEED position. The differential must be unlocked. |
Cylinder Cycle Time - Check
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Table 9
Status(1) |
Description |
Specification |
Actual |
Comments |
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Cylinder Drift Per Minute |
3.0 mm/ min (0.12 inch/ min) Maximum |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Hydraulic and Steering System
Reference: Refer to Testing and Adjusting, KENR8413, "Hydraulic and Steering System" for more detail on the following test.
Pump Control Valve (Hydraulic, Steering) - Test and Adjust
Low Standby Pressure Adjustment
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Table 10
Status(1) |
Description |
Specification |
Actual |
Comments |
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Low-Pressure Standby at HIGH IDLE |
3300 ± 689 kPa (480 ± 100 psi) |
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True Low-Pressure Standby at HIGH IDLE |
2100 ± 150 kPa (305 ± 22 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Adjustment for Flow Compensator (Margin Pressure)
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Table 11
Status(1) |
Description |
Specification |
Actual |
Comments |
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Flow Compensator (Margin Pressure) at HIGH IDLE |
2100 ± 150 kPa (305 ± 22 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Adjustment for Hydraulic System Pressure
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Table 12
Status(1) |
Description |
Specification |
Actual |
Comments |
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Implement Cylinder Stall Pressure at HIGH IDLE |
24132 ± 1034 kPa (3500 ± 150 psi) |
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Implement Relief Valve Pressure at HIGH IDLE |
27600 ± 400 kPa (3900 ± 60 psi) |
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25500 ± 350 kPa (3700 ± 70 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Adjustment for Signal Network
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Table 13
Status(1) |
Description |
Specification |
Actual |
Comments |
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Signal Network Pressure at HIGH IDLE |
3300 ± 689 kPa (480 ± 100 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Implement) - Test and Adjust
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Table 14
Status(1) |
Description |
Specification |
Actual |
Comments |
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Relief Valve Pressure |
27600 ± 400 kPa (3900 ± 60 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Disc Pack Preload for Circle Drive - Adjust
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Table 15
Status(1) |
Description |
Specification |
Actual |
Comments |
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Spring Deflection |
2.30 ± 0.25 mm (0.091 ± 0.010 inch) |
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Minimum thickness to reuse clutch disk |
2.14 mm (0.084 inch) |
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Minimum thickness to reuse clutch disk |
0.20 mm (0.008 inch) |
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(1) |
N = Normal, M = Monitor, A = Action |
Steering Wheel Slip - Check
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Table 16
Status(1) |
Description |
Specification |
Actual |
Comments |
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Maximum Steering Pressure |
18616 ± 689 kPa (2700 ± 100 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Steering) - Test and Adjust
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Table 17
Status(1) |
Description |
Specification |
Actual |
Comments |
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Relief Valve (Steering) - Test and Adjust |
22100 ± 200 kPa (3205 ± 29 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Air and Brake System
Reference: Refer to Testing and Adjusting, KENR8415, "Air System and Brakes" for more detail on the following test.
Air Pressure Gauge - Test
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Table 18
Status(1) |
Description |
Specification |
Actual |
Comments |
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Pressure difference between Air Pressure Gauge and Test Pressure Gauge for Right or Left Tank gauge |
35 kPa (5 psi) Maximum |
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(1) |
N = Normal, M = Monitor, A = Action |
Air Compressor Governor - Test and Adjust
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Table 19
Status(1) |
Description |
Specification |
Actual |
Comments |
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Cut IN, Pressure |
793 ± 34 kPa (115 ± 5 psi) |
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Cut OUT, Pressure |
1000 ± 34 kPa (145 ± 5 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Pressure Switch (Low Brake Air) - Test
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Table 20
Status(1) |
Description |
Specification |
Actual |
Comments |
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Cut IN, Pressure |
530 ± 40 kPa (77 ± 6 psi) Approximately |
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Cut OUT, Pressure |
1000 ± 34 kPa (145 ± 5 psi) |
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Low Brake Air Pressure Alarm Test |
530 ± 40 kPa (76.87120 ± 5.80160 psi) |
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Low Brake Air Pressure - Indicator |
640 kPa (93 psi) |
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(1) |
N = Normal, M = Monitor, A = Action |
Pressure Switch (Brake Air) (Stop Lamp) - Test
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Table 21
Status(1) |
Description |
Specification |
Actual |
Comments |
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Stop Lamp Brake Air Pressure Switch Test |
60 kPa (9 psi) Approximately |
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(1) |
N = Normal, M = Monitor, A = Action |
Limit Switch (Service Brake) - Test and Adjust
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Table 22
Status(1) |
Description |
Specification |
Actual |
Comments |
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Dimension for Adjustment of the Limit Switch |
18.0 ± 2.0 mm (0.71 ± 0.08 inch) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Power Train System
Reference: Refer to Testing and Adjusting, KENR8427, "Power Train" for more detail on the following test.
Transmission Charging Pump Pressure - Test and Adjust for 120K S/N:SZN1-1485
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Table 23
Status(1) |
Description |
Specification |
Actual |
Comments |
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Transmission Charging Pump Pressure at LOW IDLE |
2750 ± 70 kPa (399 ± 10 psi)(2) |
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Transmission Charging Pump Pressure at HIGH IDLE |
3150 ± 150 kPa (457 ± 22 psi)(2) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Neutral position |
Power Train Charge System Pressure - Test and Adjust for 120K S/N:SZN1486-UP
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Table 24
Status(1) |
Description |
Specification |
Actual |
Comments |
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Transmission Charging Pump Pressure at 800 RPM |
2610 ± 70 kPa (379 ± 10 psi)(2) |
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Transmission Charging Pump Pressure at 2000 RPM |
2835 ± 70 kPa (411 ± 10 psi)(2) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Neutral position |
Transmission Lubrication Oil Pressure - Test for 120K S/N:SZN1-1485
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Table 25
Status(1) |
Description |
Specification |
Actual |
Comments |
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Transmission Lubrication Oil Pressure at HIGH IDLE in NEUTRAL position |
517 ± 172 kPa (75 ± 25 psi) |
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Transmission Lubrication Oil Pressure at HIGH IDLE in FIRST GEAR FORWARD position |
152 ± 48 kPa (22 ± 7 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Transmission Lubrication Oil Pressure - Test for 120K S/N:SZN1486-UP
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Table 26
Status(1) |
Description |
Specification |
Actual |
Comments |
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Transmission Lubrication Oil Pressure in NEUTRAL position at 2000 RPM |
643 ± 228 kPa (93 ± 33 psi) |
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Transmission Lubrication Oil Pressure in FIRST GEAR FORWARD position at 2000 RPM |
179 ± 48 kPa (26 ± 7 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Transmission Pressures - Test for 120K S/N:SZN1-1485
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Table 27
Status(1) |
Description |
Specification |
Actual |
Comments |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 1 (First Gear, Forward) |
2265 ± 95 kPa (329 ± 14 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 2 (Second Gear, Forward) |
2350 ± 95 kPa (341 ± 14 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 3 (First Gear, Reverse) |
2295 ± 95 kPa (333 ± 14 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 4 (Second Gear, Forward) |
2055 ± 150 kPa (298 ± 22 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 5 (Neural) |
2888 ± 132 kPa (419 ± 19 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 6 (First Gear, Forward or Reverse) |
2740 ± 115 kPa (397 ± 17 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 7 (First Gear, Forward or Reverse) or (Second, Forward) |
2675 ± 140 kPa (388 ± 20 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 8 (Neutral) |
2680 ± 130 kPa (389 ± 19 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Transmission Pressures - Test for 120K S/N:SZN1486-UP
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Table 28
Status(1) |
Description |
Specification |
Actual |
Comments |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 1 (First Gear, Forward) |
2758 ± 69 kPa (400 ± 10 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 2 (Second Gear, Forward) |
2758 ± 69 kPa (400 ± 10 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 3 (First Gear, Reverse) |
2758 ± 69 kPa (400 ± 10 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 4 (Second Gear, Forward) |
2758 ± 69 kPa (400 ± 10 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 5 (Neural) |
2758 ± 69 kPa (400 ± 10 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 6 (First Gear, Forward or Reverse) |
2758 ± 69 kPa (400 ± 10 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 7 (First Gear, Forward or Reverse) or (Second, Forward) |
2758 ± 69 kPa (400 ± 10 psi) |
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Transmission Clutch Pressure with Differential Lock OFF at Clutch 8 (Neutral) |
2758 ± 69 kPa (400 ± 10 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Drive Chain - Check for 120K
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Table 29
Status(1) |
Description |
Specification |
Actual |
Comments |
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Chain Pitch |
50.8 mm (2.00 inch) |
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Number of Chain Links |
12 |
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New Measurement |
609.6 mm (24 inch) |
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Measurement of Maximum Wear |
628.7 mm (25 inch) |
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Chain Tension(2) |
277 kg (611 lb) |
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(1) |
N = Normal, M = Monitor, A = Action |
(2) |
The chain is put into tension in order to displace oil between the components of the chain. This will help to ensure metal-to-metal contact between the components. This will also ensure an accurate measurement. |
Tandem - Check for 120K
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Table 30
Status(1) |
Description |
Specification |
Actual |
Comments |
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Tandem - Check |
5.0 mm (0.12 inch) |
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(1) |
N = Normal, M = Monitor, A = Action |
Differential Lock Pressure - Check
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Table 31
Status(1) |
Description |
Specification |
Actual |
Comments |
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Differential Lock Pressure |
2410 kPa (350 psi) minimum |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Clutch Control - Test for 120K S/N:SZN1-1485
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Table 32
Status(1) |
Description |
Specification |
Actual |
Comments |
Clutch Not Depressed |
Clutch Depressed |
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First Gear FORWARD |
2265 ± 180 kPa (329 ± 26 psi) minimum |
0 to 21 kPa (0 to 3 psi) |
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Second Gear FORWARD |
2350 ± 95 kPa (341 ± 14 psi) |
0 to 21 kPa (0 to 3 psi) |
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First Gear REVERSE |
2295 ± 150 kPa (333 ± 22 psi) |
0 to 21 kPa (0 to 3 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Clutch Control - Test 120K S/N:SZN1486-UP
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Table 33
Status(1) |
Description |
Specification |
Actual |
Comments |
Clutch Not Depressed |
Clutch Depressed |
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First Gear FORWARD |
2758 ± 69 kPa (400 ± 10 psi) |
0 to 21 kPa (0 to 3 psi) |
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Second Gear FORWARD |
2758 ± 69 kPa (400 ± 10 psi) |
0 to 21 kPa (0 to 3 psi) |
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First Gear REVERSE |
2758 ± 69 kPa (400 ± 10 psi) |
0 to 21 kPa (0 to 3 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
S.O.S
Reference: Refer to Operation and Maintenance Manual, SEBU8250, "Maintenance Interval Schedule" for more detail on the following test.
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Table 34
Status(1) |
Description |
Obtain |
Comments |
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Engine Coolant Sample (Level 1) |
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Engine Coolant Sample (Level 2) |
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Engine Oil Sample |
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Hydraulic Oil Sample |
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Transmission/Differential Oil Sample |
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Tandem Drive Oil Sample |
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Wheel Bearing Oil Sample (Front) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |