789D Off-Highway Trucks TA2 Technical Inspection: (S/N: SPD1-UP; SHH1-UP)

Electrical System

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).
	Battery Test (2)	12.4 VDC or more
	Charging System Test (3) (4)	18 VDC to 32 VDC
	Electric Starting System Test (5)	12 to 16 V at −23° C (−10° F) to −7° C (19° F)
		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
( 2 )	Refer to Special Instruction, SEHS7633, "Battery Test Procedure".
( 3 )	Refer to Special Instruction, REHS0354, "Charging System Troubleshooting".
( 4 )	Refer to Special Instruction, SENR7503, "Delco-Remy Bulletin 1G-255".
( 5 )	Refer to Testing and Adjusting, KENR5291, "Electric Starting System - Test".

Engine

Fuel System

Table 2

Status (1)	Description	Specification	Actual	Comments
	Fuel Pressure	324 kPa (47 psi) to 648 kPa (94 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 3

Status (1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	324 kPa (47 psi)
	Engine Oil Pressure at High Idle	421 kPa (61 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Basic Engine

Table 4

Status (1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle	700 rpm
	Engine Speed at High Idle	1937 rpm
	Torque Converter Stall Test Engine RPM	1290 to 1310 rpm

( 1 )

N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

Table 5

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Stall Test Boost Pressure	134 kPa (39.5 inch mercury) to 181 kPa (53.5 inch mercury)

( 1 )

N = Normal, M = Monitor, A = Action

Performance Checks

ReferenceRefer to Testing & Adjusting, UENR1067, "Hydraulic Systems" for more detail on the following test.

Operational Checks

Table 6

Status (1)	Description	Specification	Actual	Comments
	Raise the Dump Body	19 seconds
	Front Suspension Group exposed chrome	20 mm (.79 inch)
	Rear Suspension Group exposed chrome	76.5 mm (3.0 inch)
	Toe Out Measurement	48.5 mm (1.91 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic System

ReferenceRefer to Testing & Adjusting, UENR1067, "Hydraulic Systems" for more detail on the following tests.

Hoist Cylinder Performance - Test

Table 7

Acceptable Cylinder Drift
Status (1)	Minutes	Oil Temperature	Cylinder Drift	Actual	Comments
	12.4	38°C (100°F)	6.40 mm (0.25 inch)
	9.6	43°C (110°F)	6.40 mm (0.25 inch)
	7.8	49°C (120°F)	6.40 mm (0.25 inch)
	6.4	54°C (130°F)	6.40 mm (0.25 inch)
	5.3	60°C (140°F)	6.40 mm (0.25 inch)
	4.4	66°C (150°F)	6.40 mm (0.25 inch)
	3.8	71°C (160°F)	6.40 mm (0.25 inch)
	3.2	77°C (170°F)	6.40 mm (0.25 inch)
	2.8	82°C (180°F)	6.40 mm (0.25 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Hoist Dual Stage) - Test and Adjust

Table 8

Status (1)	Description	Specification	Actual	Comments
	High Pressure	17225 to 17925 kPa (2500 to 2600 psi)
	Low Pressure	3450 to 3800 kPa (500 to 550 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Rear Brake Oil Cooler) - Test and Adjust

Table 9

Status (1)	Description	Specification	Actual	Comments
	Minimum Pressure	790 ± 20 kPa (115 ± 3 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Gear Pump (Hoist and Rear Brake Cooling) Efficiency - Test

Table 10

Status (1)	Description	Specification	Actual	Comments
	Maximum percent flow loss	10%

( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, UENR1063, "Power Train System" for more detail on the following test.

Relief Valve (Torque Converter Outlet) Pressure - Test and Adjust

Table 11

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure	345 to 552 kPa (50 to 80 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Torque Converter Inlet) Pressure - Test and Adjust

Table 12

Status (1)	Description	Specification	Actual	Comments
	Relief Pressure	930 ± 35 kPa (135 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Supply Pressure - Test and Adjust

Table 13

Status (1)	Description	Specification	Actual	Comments
	Pressure	4690 ± 200 kPa (680 ± 29 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pilot Pressure - Test and Adjust

Table 14

Status (1)	Description	Specification	Actual	Comments
	Pressure	1725 ± 70 kPa (250 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Leakage - Test

Table 15

Status (1)	Description	Specification	Actual	Comments
	Maximum flow rate	3.8 L/min (1 US gpm)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Signal Pressure - Test

Table 16

Status (1)	Description	Specification	Actual	Comments
	Pressure	1725 kPa (250 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Maximum Pressure - Test

Table 17

Status (1)	Description	Specification	Actual	Comments
	Pressure	2140 ± 70 kPa (310 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Primary Pressure - Test and Adjust

Table 18

Status (1)	Description	Specification	Actual	Comments
	Pressure	1030 ± 35 kPa (150 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Gear Pump (Transmission Charging) Pressure - Test and Adjust

Table 19

Status (1)	Description	Specification	Actual	Comments
	Low Idle	2515 kPa (365 psi)
	High Idle	3175 kPa (461 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Dual Stage Relief Valve Pressure - Test and Adjust

Table 20

Status (1)	Description	Specification	Actual	Comments
	Low Idle	2515 kPa (365 psi)
	Medium Idle - lockup clutch solenoid engaged	2100 ± 105 kPa (305 ± 15 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Clutch Pressure - Test

Table 21

Speed	N-1	N-2	R	1	2	3	4	5	6
Engaged Clutches	3	1	1, 6	1, 5	2, 5	1, 4	2, 4	1, 3	2, 3
Stations	"C"	"B"	"B", "G"	"B", "F"	"A", "F"	"B ", "E"	"A", "E"	"B", "C"	"A", "C"

Table 22

Measurements of the Clutch Pressure
Station (1)	"A"	"B"	"C"	"D" (2)	"E"	"F"	"G"
Low Idle (3) Pressure (4)	N/A	2760 kPa (400 psi)	N/A	N/A	N/A	2585 kPa (375 psi)	2760 kPa (400 psi)
Actual	N/A		N/A	N/A	N/A
High Idle (3) Pressure (4)	N/A	2890 kPa (419 psi) (5)	2470 kPa (358 psi)	N/A	N/A	2720 kPa (395 psi)	2805 kPa (407 psi)
Actual	N/A			N/A	N/A
1300 rpm (6) Pressure (4)	2020 kPa (293 psi)	2020 kPa (293 psi)	2020 kPa (293 psi)	N/A	2020 kPa (293 psi)	2020 kPa (293 psi)	N/A
Actual				N/A			N/A

( 1 )	Station "H" is not used.
( 2 )	Station "D" does not control a clutch. Station "D" controls the dual stage relief valve for the system pressure.
( 3 )	Torque converter drive
( 4 )	The tolerance is + 240 − 100 kPa (+ 35 − 15 psi), except when the pressure is noted otherwise.
( 5 )	The tolerance is + 225 − 225 kPa (+ 33 − 33 psi).
( 6 )	Direct drive

Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust

Table 23

Speed	N-1	N-2	R	1	2	3	4	5	6
Engaged Clutches	3	1	1, 6	1, 5	2, 5	1, 4	2, 4	1, 3	2, 3
Stations	"C"	"B"	"B", "G"	"B", "F"	"A", "F"	"B ", "E"	"A", "E"	"B", "C"	"A", "C"

Table 24

Measurements of the Primary Clutch Pressure
Station (1)	"A"	"B"	"C"	"D" (2)	"E"	"F"	"G"
Low Idle Pressure (3)	525 kPa (76.1 psi)	475 kPa (68.9 psi)	480 kPa (69.6 psi)	N/A	425 kPa (61.6 psi)	450 kPa (65.3 psi)	425 kPa (61.6 psi)
Actual				N/A

( 1 )	Station "H" is not used.
( 2 )	Station "D" does not control a clutch. Station "D" controls the dual stage relief valve for the system pressure.
( 3 )	The tolerance is +50 − 35 (+7 − 5).

Lubrication Relief Valve (Transmission) Pressure - Test

Table 25

Status (1)	Description	Specification	Actual	Comments
	Low Idle	4 kPa (0.6 psi) minimum
	High Idle	140 to 205 kPa (20 to 30 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Pilot Pressure - Test and Adjust

Table 26

Status (1)	Description	Specification	Actual	Comments
	Pressure	1755 ± 35 kPa (255 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering System

ReferenceRefer to Testing & Adjusting, UENR1069, "Steering System" for more detail on the following test.

Piston Pump (Steering) Pressure - Test and Adjust

Table 27

Status (1)	Description	Specification	Actual	Comments
	High Pressure Cutoff Valve	20000 ± 350 kPa (2900 ± 50 psi)
	Low Pressure Cut-in Valve	2000 to 3600 kPa (290 to 522 psi)
	Accumulator Charging Valve	18300 ± 350 kPa (2655 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering) - Test and Adjust

Table 28

Status (1)	Description	Specification	Actual	Comments
	Pressure	20700 ± 400 kPa (3002 ± 58 psi) @ 8 ± 2 L/min (2.1 ± 0.5 US gpm)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Accumulator - Test and Charge

Table 29

Charging Pressure and Temperature Relationship for the Steering Accumulators
Temperature	Pressure (1)
−7°C (20°F)	5005 kPa (726 psi)
−1°C (30°F)	5060 kPa (734 psi)
4°C (40°F)	5170 kPa (750 psi)
10°C (50°F)	5280 kPa (766 psi)
16°C (60°F)	5390 kPa (782 psi)
21°C (70°F)	5500 kPa (798 psi)
27°C (80°F)	5610 kPa (814 psi)
32°C (90°F)	5720 kPa (830 psi)
38°C (100°F)	5830 kPa (846 psi)
43°C (110°F)	5940 kPa (862 psi)
49°C (120°F)	5995 kPa (870 psi)

( 1 )

The allowable tolerance on nominal pressure is 70 kPa (10 psi).

Braking System

ReferenceRefer to Testing & Adjusting, UENR1073, "Braking System" for more detail on the following test.

Parking Brake System Pressure - Test and Adjust

Table 30

Status (1)	Description	Specification	Actual	Comments
	Pressure	4690 ± 200 kPa (680 ± 29 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Service Brake Discs - Check - Standard

Table 31

Baseline Value for the Piston Stroke (1)
Front Wheels	Rear Wheels
4.4 mm (0.173 inch)	5.8 mm (0.228 inch)

( 1 )

The baseline is the piston stroke that is measured through the service port. This value can float by 2 to 3 mm (0.0787 to 0.1181 inch) due to tolerances.

Table 32

Additional Piston Stroke (Compared to the Baseline Value for the Piston Stroke from Table 31)
Percent of Brake Wear	Front Brake Piston Travel	Rear Brake Piston Travel
10 percent	0.6 mm (0.0236 inch)	0.9 mm (0.0354 inch)
20 percent	1.2 mm (0.0472 inch)	1.8 mm (0.0708 inch)
30 percent	1.8 mm (0.0709 inch)	2.6 mm (0.1024 inch)
40 percent	2.4 mm (0.0945 inch)	3.5 mm (0.1378 inch)
50 percent	3.0 mm (0.1181 inch)	4.4 mm (0.1732 inch)
60 percent	3.5 mm (0.1378 inch)	5.3 mm (0.2087 inch)
70 percent	4.1 mm (0.1614 inch)	6.2 mm (0.2441 inch)
80 percent	4.7 mm (0.1850 inch)	7.0 mm (0.2756 inch)
90 percent	5.3 mm (0.2087 inch)	7.9 mm (0.3110 inch)
100 percent	5.9 mm (0.2323 inch)	8.8 mm (0.3465 inch)

Table 33

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 34

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

Table 35

Status (1)	Description		Specification	Actual	Comments
	Retarder On	Rear slack adjuster	3650 kPa (530 psi)
		Front slack adjuster	3650 kPa (530 psi)
		Rear brake master cylinder	550 kPa (80 psi)
	Retarder Off	Rear slack adjuster	5445 kPa (790 psi)
		Front slack adjuster	5445 kPa (790 psi)
		Rear brake master cylinder	655 to 827 kPa (95 to 120 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Slack Adjuster - Test and Adjust

Table 36

Status (1)	Description	Specification	Actual	Comments
	Residual pressure - Rear wheels	59 kPa (8.6 psi)
	Residual pressure - Front wheels	103 kPa (14.9 psi)
	Force to move piston	220 N (50 lb)

( 1 )

N = Normal, M = Monitor, A = Action

Brake Cooling Pressure - Check

Table 37

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

Relief Valve (Rear Brake Oil Cooler) - Test and Adjust

Table 38

Status (1)	Description	Specification	Actual	Comments
	Pressure	790 ± 20 kPa (115 ± 3 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Air System

ReferenceRefer to Testing & Adjusting, UENR1073, "Air System" for more detail on the following test.

Air Compressor Governor - Test and Adjust

Table 39

Status (1)	Description	Specification	Actual	Comments
	Cut in pressure	655 kPa (95 psi)
	Cut out pressure	837 ± 34 kPa (120 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

S.O.S

ReferenceRefer to Operation and Maintenance Manual, SEBU8242, "Maintenance Interval Schedule" for more detail on performing S.0.S samples.

Table 40

Status (1)	Description	Obtain		Comments
	Engine Oil Sample	Every 500 Service Hours
	Cooling System Coolant Sample (Level I)	Every 500 Service Hours
	Cooling System Coolant Sample (Level II)	Every Year
	Hoist, Torque Converter, and Brake Tank Oil Sample	Every 500 Service Hours
	Front Wheel Oil Sample	Every 500 Service Hours
	Differential and Final Drive Oil Sample	Every 500 Service Hours
	Transmission Tank Oil Sample	Every 500 Service Hours
	Steering System Oil Sample	Every 500 Service Hours

( 1 )

N = Normal, M = Monitor, A = Action MARYGAR

789D Off-Highway Trucks TA2 Technical Inspection: (S/N: SPD1-UP; SHH1-UP) 2012-12-01T07:47:00-08:00 Rating: 4.5 Diposkan Oleh: Unknown