Electrical System

Status (1)

Description
Inspect
Battery
Cables

Battery
Test (2)
Charging
System
Test (3) (4)
Electric
Starting
System
Test (5)

Table 1
Specification

Actual Comments

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).
12.4 VDC or more
18 VDC to 32 VDC

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
Status

(1)

Description
Fuel Pressure

Table 2
Specification
324 kPa (47 psi)
to

Actual

Comments

(1)

648 kPa (94 psi)

N = Normal, M = Monitor, A = Action

Lubrication System
Status (1)

(1)

Table 3
Specification

Description
Engine Oil Pressure at Low
Idle

324 kPa (47 psi)

Engine Oil Pressure at High

Idle

421 kPa (61 psi)

Actual

Comments

Actual

Comments

N = Normal, M = Monitor, A = Action

Basic Engine
Table 4
Status (1)

Description

Specification

Engine Speed at Low Idle

Engine Speed at High Idle
Torque Converter Stall Test
Engine RPM
(1)
N = Normal, M = Monitor, A = Action

700 rpm
1937 rpm
1290 to 1310
rpm

Air Inlet and Exhaust System

Table 5
Status

(1)

Description

Specification

Torque Converter Stall Test

Boost Pressure

Actual Comments

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
Raise the Dump Body
Front Suspension Group

Specification
19 seconds

Actual

Comments

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

Status (1)

Minutes

Table 7
Acceptable Cylinder Drift
Cylinder Drift
Oil
Temperature

Actual

Comments

Actual

Comments

12.4
38C (100F)

6.40 mm (0.25
inch)

43C (110F)

6.40 mm (0.25
inch)

49C (120F)

6.40 mm (0.25
inch)

54C (130F)

6.40 mm (0.25
inch)

60C (140F)

6.40 mm (0.25
inch)

66C (150F)

6.40 mm (0.25
inch)

71C (160F)

6.40 mm (0.25
inch)

77C (170F)

6.40 mm (0.25
inch)

82C (180F)

6.40 mm (0.25
inch)

9.6

7.8

6.4

5.3

4.4

3.8

3.2

2.8

(1)

N = Normal, M = Monitor, A = Action

Relief Valve (Hoist Dual Stage) - Test and Adjust

Status

(1)

Description

Table 8
Specification

High
Pressure
Low
Pressure
(1)

17225 to 17925 kPa (2500 to 2600

psi)
3450 to 3800 kPa (500 to 550 psi)

N = Normal, M = Monitor, A = Action

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

Status (1)

Description

Table 9
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
Description
Specification
Maximum percent flow loss
10%
(1)
N = Normal, M = Monitor, A = Action
Status (1)

Actual

Comments

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

Status (1)

Table 11
Specification

Description

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

Status

(1)

(1)

Description
Relief Pressure

Table 12
Specification

930 35 kPa (135 5 psi)

N = Normal, M = Monitor, A = Action

Actual

Comments

Torque Converter Lockup Clutch Supply Pressure - Test and Adjust

Status

(1)

(1)

Table 13
Specification

Description
Pressure

Actual

Comments

4690 200 kPa (680 29 psi)

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Pilot Pressure - Test and Adjust

Status (1)

(1)

Table 14
Specification

Description
Pressure

Actual

Comments

1725 70 kPa (250 10 psi)

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Leakage - Test

Status

(1)

(1)

Description
Maximum flow rate

Table 15
Specification

Actual

Comments

3.8 L/min (1 US gpm)

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Signal Pressure - Test

Status

(1)

(1)

Description
Pressure

Table 16
Specification

Actual

Comments

1725 kPa (250 psi)

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Maximum Pressure - Test

Status (1)

(1)

Description
Pressure

Table 17
Specification

Actual

Comments

2140 70 kPa (310 10 psi)

N = Normal, M = Monitor, A = Action

Torque Converter Lockup Clutch Primary Pressure - Test and Adjust

Status

(1)

(1)

Description
Pressure

Table 18
Specification

1030 35 kPa (150 5 psi)

N = Normal, M = Monitor, A = Action

Actual

Comments

Gear Pump (Transmission Charging) Pressure - Test and Adjust

Status

(1)

Table 19
Specification

Description
Low Idle

Actual

Comments

2515 kPa (365 psi)

High Idle
(1)

3175 kPa (461 psi)

N = Normal, M = Monitor, A = Action

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

(1)

Table 20
Specification

Description

Actual Comments

Low Idle
2515 kPa (365 psi)
Medium Idle - lockup clutch
solenoid engaged
(1)

2100 105 kPa (305

15 psi)

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Clutch Pressure - Test

Speed
Engaged
Clutches
Stations

N-1

N-2

1, 6

1, 5

"C"

"B"

"B",
"G"

"B",
"F"

Station (1)

"A"

Low Idle (3)

Pressure (4)

N/A

Table 21
1
2

2, 5

1, 4

2, 4

1, 3

2, 3

"A",
"F"

"B ",
"E"

"A",
"E"

"B",
"C"

"A",
"C"

Table 22
Measurements of the Clutch Pressure
"B"
"C"
"D" (2)
"E"
N/A
2760 kPa
(400 psi)

N/A

"F"

"G"

N/A
2585 kPa 2760 kPa
(375 psi) (400 psi)

Actual
High
Idle (3)
Pressure (4)

N/A
N/A

Actual
1300
rpm (6)
Pressure (4)

N/A

N/A
2890 kPa
(419
psi) (5)

N/A
N/A

N/A
N/A

2470 kPa
(358 psi)

2720 kPa 2805 kPa

(395 psi) (407 psi)
N/A
N/A

2020 kPa
(293 psi)

2020 kPa
(293 psi)

N/A
N/A

2020 kPa
(293 psi)

2020 kPa 2020 kPa

(293 psi) (293 psi)

Actual
N/A
N/A
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
(1)

Transmission Hydraulic Control Primary Clutch Pressure - Test and Adjust

Speed
Engaged
Clutches
Stations

Station (1)
Low Idle
Pressure (3)

Table 23
1
2

N-1

N-2

1, 6

1, 5

"C"

"B"

"B",
"G"

"B",
"F"

2, 5

1, 4

2, 4

1, 3

2, 3

"A",
"F"

"B ",
"E"

"A",
"E"

"B",
"C"

"A",
"C"

Table 24
Measurements of the Primary Clutch Pressure
"A"
"B"
"C"
"D" (2)
"E"

"F"

"G"

N/A
525 kPa
(76.1 psi)

475 kPa
(68.9 psi)

480 kPa
(69.6 psi)

425 kPa
(61.6 psi)

450 kPa
(65.3 psi)

425 kPa
(61.6 psi)

Actual
N/A
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).
(1)

Lubrication Relief Valve (Transmission) Pressure - Test

Table 25

Status (1)

Description
Low Idle

Specification

Actual

Comments

4 kPa (0.6 psi) minimum

High Idle
(1)

140 to 205 kPa (20 to 30 psi)

N = Normal, M = Monitor, A = Action

Transmission Hydraulic Control Pilot Pressure - Test and Adjust

Status

(1)

(1)

Description
Pressure

Table 26
Specification

Actual

Comments

1755 35 kPa (255 5 psi)

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

Status

(1)

Description

Table 27
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
(1)

18300 350 kPa (2655

50 psi)

N = Normal, M = Monitor, A = Action

Relief Valve (Steering) - Test and Adjust

Status (1)

Description

Table 28
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)
7C (20F)

5005 kPa (726 psi)

1C (30F)

5060 kPa (734 psi)

(1)

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)
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

Status

(1)

Description
Pressure

Table 30
Specification

Actual

Comments

(1)

4690 200 kPa (680 29 psi)

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
Retarder
On

Retarder
Off

(1)

Specification

Rear slack
adjuster
Front slack
adjuster
Rear brake
master cylinder
Rear slack
adjuster
Front slack
adjuster
Rear brake
master cylinder

Actual Comments

3650 kPa (530 psi)

3650 kPa (530 psi)
550 kPa (80 psi)
5445 kPa (790 psi)
5445 kPa (790 psi)
655 to 827 kPa (95 to
120 psi)

N = Normal, M = Monitor, A = Action

Slack Adjuster - Test and Adjust

Status

(1)

Description

Table 36
Specification

Residual pressure - Rear

wheels
Residual pressure - Front
wheels

Actual

59 kPa (8.6 psi)

103 kPa (14.9 psi)

Force to move piston

220 N (50 lb)
(1)

N = Normal, M = Monitor, A = Action

Brake Cooling Pressure - Check

Status

(1)

Description
Low Idle

Table 37
Specification
14 kPa (2 psi)

High Idle
(1)

172 kPa (25 psi)

N = Normal, M = Monitor, A = Action

Actual

Comments

Comments

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

Status (1)

(1)

Description
Pressure

Table 38
Specification

Actual

Comments

790 20 kPa (115 3 psi)

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

Status

(1)

Description

Table 39
Specification

Actual

Comments

Cut in pressure
655 kPa (95 psi)
Cut out pressure
(1)

837 34 kPa (120 5 psi)

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
(1)
Status
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

MARYGAR

Every 500 Service

Hours
Every 500 Service
Hours
Every Year
Every 500 Service
Hours
Every 500 Service
Hours
Every 500 Service
Hours
Every 500 Service
Hours
Every 500 Service
Hours