966H/972H Wheel Loader TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565} Caterpillar

Wheel Loader:

966H (S/N: BJ61-UP)

972H (S/N: WXZ1-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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1. Click format to print.

2. Save the document as an HTML format.

3. Open the document with Microsoft Word.

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	12.4 VDC or more		Refer to Special Instruction, SEHS7633, "Battery Test Procedure".
	Charging System Test	18 VDC to 32 VDC		Refer to Special Instruction, REHS0354, "Charging System Troubleshooting".
	Electric Starting System Test	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

Engine

Cooling System

Table 2

Status (1)	Description	Specification	Actual	Comments
	Radiator Pressure Relief (Radiator Cap) (2)	-
	Freezing Point of Engine Coolant	-
	Conditioner Test of Engine Coolant	-
	Belt Tension	-		Refer to Operation and Maintenance Manual.

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Test for the pressure that is listed on the cap.

Fuel System

Table 3

Status (1)	Description	Specification	Actual	Comments
	Fuel Pressure	655 ± 206 kPa (95 ± 30 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status (1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	62.05284 to 179 kPa (9 psi to 26 psi)
	Engine Oil Pressure at Full Load Speed	275 to 406 kPa (40 to 59 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Basic Engine

Table 5

Status (1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle	825 ± 10 rpm
	Engine Speed at High Idle	2270 ± 40 rpm
	Torque Converter Stall Test Engine RPM	1400 ± 10 rpm
	Cylinder Cutout Test	-		Cat® Electronic Technician (Cat ET) Service Tool
	Engine Crankcase Pressure (Blowby)	-

( 1 )

N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

Table 6

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Stall Test Boost Pressure	125.97371 ± 20.3 kPa (37.2 ± 6 inch mercury)
	Cylinder # 1 Exhaust Temperature (2)	-
	Cylinder # 2 Exhaust Temperature (2)	-
	Cylinder # 3 Exhaust Temperature (2)	-
	Cylinder # 4 Exhaust Temperature (2)	-
	Cylinder # 5 Exhaust Temperature (2)	-
	Cylinder # 6 Exhaust Temperature (2)	-
	Cylinder # 7 Exhaust Temperature (2)	-
	Cylinder # 8 Exhaust Temperature (2)	-

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	Compare the exhaust temperature variance at each exhaust port.

Hydraulic Performance Checks

ReferenceRefer to Testing & Adjusting, UENR1694, "966H, 972H, and 980H Wheel Loaders Electrohydraulic Electronic Control System" for more detail on the following test.

Implement Cycle Time-Check

Table 7

Status (1)	Model	Description	Specification	Actual	Comments
	966H	Lift Raise	6.5 ± 0.5 sec
		Lift Lower	3.5 ± 0.5 sec
		Float	2.8 ± 0.5 sec
		Tilt Back	2.5 ± 0.5 sec
		Dump	2.7 ± 0.5 sec
	972H	Lift Raise	6.5 ± 0.5 sec
		Lift Lower	3.5 ± 0.5 sec
		Float	2.8 ± 0.5 sec
		Tilt Back	3.4 ± 0.5 sec
		Dump	3.3 ± 0.5 sec

( 1 )

N = Normal, M = Monitor, A = Action

Lift and Tilt Cylinder Drift - Check

Table 8

Status (1)	Model	Description	Specification	Actual	Comments
	966H and 972H	Oil Temperature	49 to 65° C (120 to 150° F)
		Lift Cylinder	14 mm (0.6 inch) over 5 minutes
		Tilt Cylinder	20 mm (0.8 inch) over 5 minutes

( 1 )

N = Normal, M = Monitor, A = Action

Brake Performance Checks

ReferenceRefer to Testing & Adjusting, UENR1691, "966H and 972H Wheel Loaders Braking and Hydraulic Fan System" for more detail on the following test.

Table 9

Status (1)	Description	Specification	Actual	Comments
	Brake Accumulator - Test (Test from OMM)	6201 kPa (900 psi) at 21° C (70° F)
	Service Brake Holding Ability Test- Test (Test from OMM)
	Parking Brake Holding Ability Test- Test (Test from OMM)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Performance Checks

ReferenceRefer to Testing & Adjusting, UENR1689, "966H and 972H Wheel Loaders Steering System" for more detail on the following test.

Command Control Steering Time - Check

Table 10

Status (1)	Description	Specification	Actual	Comments
	Steering Time for a Full Turn from Stop to Stop (High Idle)	2.9 ± 0.5 Seconds

( 1 )

N = Normal, M = Monitor, A = Action

HMU Steering Time - Check

Table 11

Status (1)	Description	Specification	Actual	Comments
	Steering Time for a Full Turn from Stop to Stop (High Idle)	2.9 ± 0.5 Seconds

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic System

ReferenceRefer to Testing & Adjusting, UENR1694, "966H, 972H, and 980H Wheel Loaders Electrohydraulic Electronic Control System" for more detail on the following test.

Implement Piston Pump Margin Pressure (Float)

Table 12

Status (1)	Description	Specification	Actual	Comments
	Implement Piston Pump Margin Pressure (Float)	2100 ± 100 kPa (300 ± 15 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Pilot Pressure to the Main Control Valve

Table 13

Status (1)	Description	Specification	Actual	Comments
	Pilot Pressure to the Main Control Valve	3450 ± 150 kPa (500 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Load Sensing Signal Relief Valve - Test and Adjust

Table 14

Status (1)	Description	Specification	Actual	Comments
	Load Sensing Signal Relief Valve - Test and Adjust	28900 ± 700 kPa (4200 ± 100 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Pilot Oil Accumulator (Dead Engine Lower) - Test

Table 15

Status (1)	Description	Specification	Actual	Comments
	Oil Temperature	21° C (70° F)
	Accumulator Pressure (High Idle)	3515 ± 345 kPa (510 ± 50 psi)
	Accumulator Pressure (Dead Engine Lower)	1000 ± 50 kPa (145 ± 7 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Table 16

Charging Pressure and Temperature Relationship for a Typical 1000 kPa (145 psi) Accumulator
Temperature	Pressure
−7 °C (20 °F)	906 kPa (131 psi)
−1 °C (30 °F)	925 kPa (134 psi)
4 °C (40 °F)	943 kPa (137 psi)
10 °C (50 °F)	962 kPa (140 psi)
16 °C (60 °F)	981 kPa (142 psi)
21 °C (70 °F)	1000 kPa (145 psi)
27 °C (80 °F)	1019 kPa (148 psi)
32 °C (90 °F)	1038 kPa (151 psi)
38 °C (100 °F)	1057 kPa (153 psi)
43 °C (110 °F)	1075 kPa (156 psi)
49 °C (120 °F)	1094 kPa (159 psi)

Ride Control Accumulator - Test

Table 17

Status (1)	Description	Specification	Actual	Comments
	Oil Temperature	21° C (70° F)
	Charge Pressure (at Ambient Temperature)	2300 kPa (334 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Table 18

Charging Pressure and Temperature Relationship for a Typical 2300 kPa (334 psi) Accumulator
Temperature	Pressure
−7 °C (20 °F)	2083 kPa (302 psi)
−1 °C (30 °F)	2126 kPa (308 psi)
4 °C (40 °F)	2170 kPa (315 psi)
10 °C (50 °F)	2213 kPa (321 psi)
16 °C (60 °F)	2257 kPa (327 psi)
21 °C (70 °F)	2300 kPa (334 psi)
27 °C (80 °F)	2343 kPa (340 psi)
32 °C (90 °F)	2387 kPa (346 psi)
38 °C (100 °F)	2430 kPa (352 psi)
43 °C (110 °F)	2474 kPa (359 psi)
49 °C (120 °F)	2517 kPa (365 psi)

Power Train System

ReferenceRefer to Testing & Adjusting, UENR1625, "966H, 972H, and 980H Wheel Loaders Power Train Electronic Control System" for more detail on the following test.

Tire Pressure

Proper tire inflation pressure and maintenance of the tire inflation pressure is critical for optimum tire life. The tire inflation pressure should always be obtained from the tire supplier due to changes in the technology of tires, equipment, and job applications. Refer to Operation and Maintenance Manual, SEBU9146, "Tire Inflation Information" for information on tire inflation.

Also refer to the latest edition of Special Publication, "Caterpillar Performance Handbook" for general information on tire inflation pressure.

Calibrate Fill time for the Transmission Clutch

Refer to Testing and Adjusting, UENR1625, "Fill Time for the Transmission Clutch (Electronic Technician) - Calibrate" for information on calibrating the fill time for the transmission clutch.

Test for the Transmission Clutch Pressure

Table 19

Status (1)	Description	Specification	Actual	Comments
	Clutch "1" Pressure (Reverse in Any Speed)	2758 ± 140 kPa (400 ± 20 psi)
	Clutch "2" Pressure (Forward in Any Speed)	2758 ± 140 kPa (400 ± 20 psi)
	Clutch "3" Pressure (Neutral)	2758 ± 140 kPa (400 ± 20 psi)
	Clutch "4" Pressure (Forward or Reverse/Third Speed)	2758 ± 140 kPa (400 ± 20 psi)
	Clutch "5" Pressure (Second Speed/Forward or Reverse)	2310 ± 140 kPa (335 ± 20 psi)
	Clutch "6" Pressure (First Speed/Forward or Reverse)	2758 ± 140 kPa (400 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Table 20

Speed Range and Direction	Engaged Clutches and Energized Solenoids
Fourth Speed Forward	3 and 2
Third Speed Forward	4 and 2
Second Speed Forward	5 and 2
First Speed Forward	6 and 2
Neutral	3
First Speed Reverse	6 and 1
Second Speed Reverse	5 and 1
Third Speed Reverse	4 and 1
Fourth Speed Reverse	3 and 1

Torque Converter Inlet Pressure (High Idle)

Table 21

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Inlet Pressure (High Idle)	925 ± 50 kPa (135 ± 7.5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Torque Converter Outlet Pressure (Torque Converter Stall)

Table 22

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Outlet Pressure (Torque Converter Stall)	415 ± 140 kPa (60 ± 20 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Lubrication Pressure (High Idle)

Table 23

Status (1)	Description	Specification	Actual	Comments
	Transmission Lubrication Pressure (High Idle)	105 kPa (15 psi) (minimum)

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Oil Pump Pressure (High Idle)

Table 24

Status (1)	Description	Specification	Actual	Comments
	Transmission Oil Pump Pressure (High Idle)	2758 ± 70 kPa (400 ± 10 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering System

ReferenceRefer to Testing & Adjusting, UENR1689, "966H and 972H Wheel Loaders Steering System" for more detail on the following test.

Piston Pump (Steering) High Pressure Stall - Test

Table 25

Status (1)	Description	Specification	Actual	Comments
	Piston Pump (Steering) High Pressure Stall - Test	20700 ± 700 kPa (3000 ± 100 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Margin Pressure - Test

Table 26

Status (1)	Description	Specification	Actual	Comments
	Margin Pressure	2400 kPa (348 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Low Pressure Standby - Test

Table 27

Status (1)	Description	Specification	Actual	Comments
	Piston Pump (Steering) Low Pressure Standby (High Idle)	3500 ± 345 kPa (500 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

HMU Steering Cylinder Crossover Relief Valve - Test

Table 28

Status (1)	Description	Specification	Actual	Comments
	HMU Steering Cylinder Crossover Relief Valve - Test	25600 ± 700 kPa (3700 ± 100 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Command control Steering Pilot System Pressure - Test

Table 29

Status (1)	Description	Specification	Actual	Comments
	Left Steering Pilot Pressure (Min)	1600 to 3000 kPa (232 to 435 psi)
	Right Steering Pressure (Min)	1600 to 3000 kPa (232 to 435 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Command Control Steering Pilot Valve Supply Pressure - Test

Table 30

Status (1)	Description	Specification	Actual	Comments
	Steering Pilot Pressure	3515 ± 345 kPa (510 ± 50 psi)
	Neutral Pilot Pressure	600 ± 35 kPa (87 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Neutralizer Valve - Check

Table 31

Status (1)	Description	Specification	Actual	Comments
	Right Side Gap (Engine Frame to Non-Engine Frame	10 ± 3 mm (0.4 ± 0.1 inch)
	Left Side Gap (Engine Frame to Non-Engine Frame	10 ± 3 mm (0.4 ± 0.1 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Brake and Hydraulic Fan System

ReferenceRefer to Testing & Adjusting, UENR1691, "Braking and Hydraulic Fan System" for more detail on the following test.

Service Brake System Pressure - Test

Table 32

Status (1)	Description	Specification	Actual	Comments
	Rear Service Brake Pressure (Brake ON)	4690 ± 350 kPa (680 ± 50 psi)
	Front Service Brake Pressure (Brake ON)	4690 ± 350 kPa (680 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Service Brake Wear Indicator

Table 33

Disc Thickness Wear Chart
Estimated Percentage of Remaining Brake Disc Life	Amount of Friction Material that is Worn From the Disc	Oil Groove Depth (1)
100	0.00 mm (.000 inch)	1.05 mm (.041 inch)
80	0.29 mm (.011 inch)	0.90 mm (.036 inch)
60	0.58 mm (.023 inch)	0.76 mm (.030 inch)
40	0.88 mm (.034 inch)	0.61 mm (.024 inch)
20	1.17 mm (.046 inch)	0.47 mm (.018 inch)
0	1.46 mm (.058 inch)	0.32 mm (.013 inch)

( 1 )

Groove depth is the most critical measurement.

Hydraulic Fan (If Equipped)

Table 34

Status (1)	Description	Specification	Actual	Comments
	Max Fan Speed	1200 ± 50 rpm
	Minimum Fan Speed	525 ± 75 rpm
	Margin Pressure (Low Idle)	1800 ± 100 kPa (261 ± 14 psi)
	High Pressure Cut Off (High Idle)	19388 ± 350 kPa (2812 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Air System

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

Pressure - Test and Adjust

Table 35

Status (1)	Description	Specification	Actual	Comments
	Low Idle	Enter Value
	High Idle	Enter Value

( 1 )

N = Normal, M = Monitor, A = Action

S·O·S Samples

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

Engine Oil Sample

Table 36

Status (1)	Description	Obtain	Comments
	Engine Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action

Engine Coolant Sample

Table 37

Status (1)	Description	Obtain	Comments
	Engine Coolant Sample

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic Oil Sample

Table 38

Status (1)	Description	Obtain	Comments
	Hydraulic Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 39

Status (1)	Description	Obtain	Comments
	Front Differential & Final Drive Oil Sample
	Rear Differential & Final Drive Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action

Differential & Final Drive Oil Samples (Outboard Final Drives)

Table 40

Status (1)	Description	Obtain	Comments
	Front Differential Oil Sample
	Rear Differential Oil Sample
	Left Front Final Drive Oil Sample
	Right Front Final Drive Oil Sample
	Left Rear Final Drive Oil Sample
	Right Rear Final Drive Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action

Transmission/Torque Converter Oil Sample

Table 41

Status (1)	Description	Obtain	Comments
	Transmission/Torque Converter Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action