values for 789d.pdf

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)


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)


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 )


Air Inlet and Exhaust System Table 5

Status (1)


Torque Converter Stall Test Boost Pressure

134 kPa (39.5 inch

mercury)

to

181 kPa (53.5 inch

mercury)


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

Operational Checks Table 6

Status (1)


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)


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

38C (100F)

6.40 mm (0.25

inch)

9.6

43C (110F)

6.40 mm (0.25

inch)

7.8

49C (120F)

6.40 mm (0.25

inch)

6.4

54C (130F)

6.40 mm (0.25

inch)

5.3

60C (140F)

6.40 mm (0.25

inch)

4.4

66C (150F)

6.40 mm (0.25

inch)

3.8

71C (160F)

6.40 mm (0.25

inch)

3.2

77C (170F)

6.40 mm (0.25

inch)

2.8

82C (180F)

6.40 mm (0.25

inch)


Relief Valve (Hoist Dual Stage) - Test and Adjust Table 8

Status (1)


High Pressure

17225 to 17925 kPa (2500 to 2600

psi)

Low Pressure

3450 to 3800 kPa (500 to 550 psi)


Relief Valve (Rear Brake Oil Cooler) - Test and Adjust Table 9

Status (1)


Comments

Minimum Pressure

790 20 kPa (115 3 psi)


Gear Pump (Hoist and Rear Brake Cooling) Efficiency - Test Table 10

Status (1)


Maximum percent flow loss 10% ( 1 )


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)


Comments

Relief Pressure

345 to 552 kPa (50 to 80 psi)


Relief Valve (Torque Converter Inlet) Pressure - Test and Adjust Table 12

Status (1)


Relief Pressure

930 35 kPa (135 5 psi)


Torque Converter Lockup Clutch Supply Pressure - Test and Adjust Table 13

Status (1)


Pressure

4690 200 kPa (680 29 psi)


Torque Converter Lockup Clutch Pilot Pressure - Test and Adjust Table 14

Status (1)


Pressure

1725 70 kPa (250 10 psi)


Torque Converter Lockup Clutch Leakage - Test Table 15

Status (1)


Maximum flow rate

3.8 L/min (1 US gpm)


Torque Converter Lockup Clutch Signal Pressure - Test Table 16

Status (1)


Pressure

1725 kPa (250 psi)


Torque Converter Lockup Clutch Maximum Pressure - Test Table 17

Status (1)


Pressure

2140 70 kPa (310 10 psi)


Torque Converter Lockup Clutch Primary Pressure - Test and Adjust Table 18

Status (1)


Pressure

1030 35 kPa (150 5 psi)


Gear Pump (Transmission Charging) Pressure - Test and Adjust Table 19

Status (1)


Low Idle

2515 kPa (365 psi)

High Idle

3175 kPa (461 psi)


Transmission Hydraulic Control Dual Stage Relief Valve Pressure - Test and

Adjust Table 20

Status (1)


Low Idle

2515 kPa (365 psi)

Medium Idle - lockup clutch solenoid engaged

2100 105 kPa (305

15 psi)


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)


Low Idle

4 kPa (0.6 psi) minimum

High Idle

140 to 205 kPa (20 to 30 psi)


Transmission Hydraulic Control Pilot Pressure - Test and Adjust Table 26

Status (1)


Pressure

1755 35 kPa (255 5 psi)


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)


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)


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)


Steering Accumulator - Test and Charge Table 29

Charging Pressure and Temperature Relationship for the Steering Accumulators

Temperature Pressure (1)

7C (20F)

5005 kPa (726 psi)

1C (30F)

5060 kPa (734 psi)

4C (40F)

5170 kPa (750 psi)

10C (50F)

5280 kPa (766 psi)

16C (60F)

5390 kPa (782 psi)

21C (70F)

5500 kPa (798 psi)

27C (80F)

5610 kPa (814 psi)

32C (90F)

5720 kPa (830 psi)

38C (100F)

5830 kPa (846 psi)

43C (110F)

5940 kPa (862 psi)

49C (120F)

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)


Pressure

4690 200 kPa (680 29 psi) ( 1 )


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)


Slack Adjuster - Test and Adjust Table 36

Status (1)


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)


Brake Cooling Pressure - Check Table 37

Status (1)


Low Idle

14 kPa (2 psi)

High Idle

172 kPa (25 psi)


Relief Valve (Rear Brake Oil Cooler) - Test and Adjust Table 38

Status (1)


Pressure

790 20 kPa (115 3 psi)


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)


Cut in pressure

655 kPa (95 psi)

Cut out pressure

837 34 kPa (120 5 psi)


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


MARYGAR

values for 789d.pdf

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