980H Wheel Loader TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar

Wheel Loader

980H (S/N: MHG1-UP; A8J1-UP; KZL1-UP; JMS1-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.

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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 - Test".
	Electric Starting System Test	12 to 16 V at −23° C (−10° F) to −7° C (19° F)		Refer to Testing and Adjusting, SENR9832, "Electrical Starting System - Test".
		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.
	Difference between the Upper and Lower Radiator Tank Temperatures	5° + 5° - 5 °C (41° + 41° - 41 °F)
	Jacket Water Inlet Temperature from Cooling System	89° ± 3°C (192° ± 5 °F)

(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 at HIGH IDLE	563 + 169 - 197 kPa (82 + 25 - 29 psi)

(1)	N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status(1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at LOW IDLE	328 + 272 - 228 kPa (48 + 39 - 33 psi)
	Engine Oil Pressure at HIGH IDLE	449 + 151 - 174 kPa (65 + 22 - 25 psi)

(1)	N = Normal, M = Monitor, A = Action

Basic Engine

Table 5

Status(1)	Description	Specification	Actual	Comments
	Engine Speed at HIGH IDLE	2200 ± 10 rpm
	Engine Speed at LOW IDLE	800 ± 10 rpm

(1)	N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

Table 6

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Oil Temperature	74° to 105°C (165° to 221° F)
	Torque Converter Stall Test Boost Pressure	123.0 ± 18.5 kPa (17.8 ± 2.7 psi)
	Engine Speed	1990 ± 65 rpm
	Cylinder # 1 Exhaust Temperature(2)	Even
	Cylinder # 2 Exhaust Temperature(2)	Even
	Cylinder # 3 Exhaust Temperature(2)	Even
	Cylinder # 4 Exhaust Temperature(2)	Even
	Cylinder # 5 Exhaust Temperature(2)	Even
	Cylinder # 6 Exhaust Temperature(2)	Even
	Cylinder # 7 Exhaust Temperature(2)	Even
	Cylinder # 8 Exhaust Temperature(2)	Even

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

Hydraulic Performance Checks

Reference: Refer to Testing & Adjusting, RENR8678, "Electrohydraulic System" for more detail on the following test.

Implement Cycle Time - Check

Table 7

Status(1)	Description	Specification	Actual	Comments
	Lift Raise Time	6.5 ± 0.5 seconds
	Lift Lower Time	3.5 ± 0.5 seconds
	Dump Time	2.5 ± 0.5 seconds
	Tilt Back Time	3.0 ± 0.5 seconds

(1)	N = Normal, M = Monitor, A = Action

Lift and Tilt Cylinder Drift - Check

Table 8

Status(1)	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes(2) for Rod Movement of Lift Cylinder	15.0 mm (0.59 inch)
	Maximum Implement Drift in 2.7 minutes(3) for Rod Movement of Lift Cylinder	15.0 mm (0.59 inch)
	Maximum Implement Drift in 1.7 minutes(4) for Rod Movement of Lift Cylinder	15.0 mm (0.59 inch)
	Maximum Implement Drift in 5.0 minutes(2) for Rod Movement of Tilt Cylinder	20.0 mm (0.79 inch)
	Maximum Implement Drift in 2.7 minutes(3) for Rod Movement of Tilt Cylinder	20.0 mm (0.79 inch)
	Maximum Implement Drift in 1.7 minutes(4) for Rod Movement of Tilt Cylinder	20.0 mm (0.79 inch)

(1)	N = Normal, M = Monitor, A = Action
(2)	Oil temperature below 38° to 49°C (100° to 120°F).
(3)	Oil temperature between 50° to 65°C (122° to 149°F).
(4)	Oil temperature between 66°C (150°F).

Brake Performance Checks

Reference: Refer to Testing & Adjusting, RENR8675, "Braking System" for more detail on the following test.

Table 9

Status(1)	Description	Specification	Actual	Comments
	Brake Accumulator - Test
	Service Brake Holding Ability Test
	Parking Brake Holding Ability Test

(1)	N = Normal, M = Monitor, A = Action

Steering Performance Checks

Reference: Refer to Testing & Adjusting, RENR8672, "Steering System" for more detail on the following test.

Steering Time - Check and Adjust

Table 10

Status(1)	Description	Specification	Actual	Comments
	Left Steering Time for a Full Turn from Stop to Stop (HIGH IDLE)	3.0 ± 0.5 seconds
	Right Steering Time for a Full Turn from Stop to Stop (HIGH IDLE)	3.0 ± 0.5 seconds
	Difference between the steering time for a right turn and the steering time for a left turn	must not be more than 0.3 seconds

(1)	N = Normal, M = Monitor, A = Action

Hydraulic System

Reference: Refer to Testing & Adjusting, RENR8678, "Electrohydraulic System" for more detail on the following test.

Pilot System Pressure - Test

Table 11

Status(1)	Description	Specification	Actual	Comments
	Pilot System Pressure at HIGH IDLE	3450 ± 200 kPa (500 ± 30 psi)
	Pilot System Pressure at Engine OFF	2070 ± 200 kPa (300 ± 30 psi)

(1)	N = Normal, M = Monitor, A = Action

Pilot Pressure to the Main Control Valve - Check

Table 12

Status(1)	Description	Specification	Actual	Comments
	Pilot Pressure at LOW IDLE	2124 ± 150 kPa (310 ± 22 psi)

(1)	N = Normal, M = Monitor, A = Action

Relief Valve (Main) - Test and Adjust

Table 13

Status(1)	Description	Specification	Actual	Comments
	Main Relief Valve Pressure for Standard Wheel Loader	20700 ± 340 kPa (3000 ± 50 psi)
	Main Relief Valve Pressure for machines with the Block Handler Conversion Arrangement	22400 ± 340 kPa (3250 ± 50 psi)

(1)	N = Normal, M = Monitor, A = Action

Relief Valve (Line) - Test and Adjust

Table 14

Status(1)	Description	Specification		Actual	Comments
		Tilt	Auxiliary
	Line Relief Valve Pressure for Head End	21700 ± 400 kPa (3150 ± 60 psi)	-
	Line Relief Valve Pressure for Rod End	14500 ± 400 kPa (2100 ± 60 psi)	-
	Line Relief Valve Pressure for Head End (Logging)	27600 ± 400 kPa (4000 ± 60 psi)	17200 ± 400 kPa (2500 ± 60 psi)
	Line Relief Valve Pressure for Rod End (Logging)	10500 ± 400 kPa (1525 ± 60 psi)	12400 ± 400 kPa (1800 ± 60 psi)

(1)	N = Normal, M = Monitor, A = Action

Ride Control Accumulator - Test and Charge

Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures" for the required tooling and the testing and charging procedure.

Specifications

Table 15

Accumulator Precharge Pressure/Temperature Relationship for a Typical Accumulator with a Precharge of 3172 kPa (460 psi)
Temperature	Pressure(1)
−7°C (20°F)	2827 kPa (410 psi)
−1°C (30°F)	2896 kPa (420 psi)
4°C (40°F)	2965 kPa (430 psi)
10°C (50°F)	3034 kPa (440 psi)
16°C (60°F)	3103 kPa (450 psi)
21°C (70°F)	3172 kPa (460 psi)
27°C (80°F)	3241 kPa (470 psi)
32°C (90°F)	3309 kPa (480 psi)
38°C (100°F)	3378 kPa (490 psi)
43°C (110°F)	3447 kPa (500 psi)
49°C (120°F)	3516 kPa (510 psi)

(1)	Nominal allowable tolerance equals ± 70 kPa (± 10 psi).

Power Train System

Reference: Refer to Testing & Adjusting, RENR8666, "Power Train System" for more detail on the following tests.

Tire Pressure

Table 16

Status(1)	Description	Specification	Actual	Comments
	Front Left Tire Pressure			See Tire Manufacture Recommendations
	Front Right Tire Pressure			See Tire Manufacture Recommendations
	Rear Left Tire Pressure			See Tire Manufacture Recommendations
	Rear Right Tire Pressure			See Tire Manufacture Recommendations

(1)	N = Normal, M = Monitor, A = Action

Torque Converter Stall - Test for 980H S/N:MHG1-3999, ; S/N:A8J1-3999, ; S/N:JMS1-3999

This test is performed using the operator monitor. Refer to Testing and Adjusting, RENR8666, "Torque Converter Stall - Test" for further instruction.

Table 17

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speeds	1990 ± 65 RPM
	Double Stall Speeds	1520 ± 100 RPM

(1)	N = Normal, M = Monitor, A = Action

Torque Converter Stall - Test for 980H S/N:MHG4000-UP, ; S/N:A8J4000-UP, ; S/N:JMS4000-UP, ; S/N:KZL1-UP

This test is performed using the operator monitor. Refer to Testing and Adjusting, RENR8666, "Torque Converter Stall - Test" for further instruction.

Table 18

Status(1)	Description	Variable Shift Control Selection	Specification	Actual	Comments
	Torque Converter Stall Speeds	ECONOMY	1990 ± 65 RPM
		INTERMEDIATE	1990 ± 65 RPM
		STANDARD	2040 ± 65 RPM
	Double Stall Speeds	ECONOMY	1520 ± 100 RPM
		INTERMEDIATE	1520 ± 100 RPM
		STANDARD	1620 ± 100 RPM

(1)	N = Normal, M = Monitor, A = Action

Transmission Pressures - Test and Adjust for 980H S/N:MHG1-3999, ; S/N:A8J1-3999, ; S/N:JMS1-3999

Table 19

Status(1)	Description	Specification	Actual	Comments
	Number 1 clutch pressure at HIGH IDLE	2275 ± 180 kPa (330 ± 25 psi)
	Number 2 clutch pressure at HIGH IDLE	2275 ± 180 kPa (330 ± 25 psi)
	Number 3 clutch pressure at HIGH IDLE	2550 ± 180 kPa (370 ± 25 psi)
	Number 4 clutch pressure at HIGH IDLE	2550 ± 180 kPa (370 ± 25 psi)
	Number 5 clutch pressure at HIGH IDLE	2275 ± 180 kPa (330 ± 25 psi)
	Number 6 clutch pressure at HIGH IDLE	2550 ± 180 kPa (370 ± 25 psi)
	Transmission Lubrication Oil Pressure at LOW IDLE	10 kPa (1.5 psi) minimum
	Transmission Lubrication Oil Pressure at HIGH IDLE	300 kPa (44 psi) minimum(2)
		120 kPa (17 psi) minimum(3)
	Torque Converter Outlet Pressure	380 kPa (55 psi) minimum and 480 kPa (70 psi) maximum(4)
	Torque Converter Inlet Pressure	660 ± 175 kPa (95 ± 25 psi) with oil at normal operating temperature
	Oil Pump Pressure	2860 ± 205 kPa (415 ± 30 psi)

(1)	N = Normal, M = Monitor, A = Action
(2)	The transmission is in THIRD speed and in NEUTRAL position.
(3)	For machines (MDA) that are equipped with a heavy-duty transmission.
(4)	The transmission is in THIRD speed and in FORWARD position. The torque converter is in a stall condition.

Transmission Pressures - Test and Adjust for 980H S/N:MHG4000-UP, ; S/N:A8J4000-UP, ; S/N:JMS4000-UP, ; S/N:KZL1-UP

Table 20

Status(1)	Description	Specification	Actual	Comments
	Number 1 clutch pressure at HIGH IDLE	2310 ± 175 kPa (335 ± 25 psi)
	Number 2 clutch pressure at HIGH IDLE	2310 ± 175 kPa (335 ± 25 psi)
	Number 3 clutch pressure at HIGH IDLE	2310 ± 175 kPa (335 ± 25 psi)
	Number 4 clutch pressure at HIGH IDLE	2310 ± 175 kPa (335 ± 25 psi)
	Number 5 clutch pressure at HIGH IDLE	2310 ± 175 kPa (335 ± 25 psi)
	Number 6 clutch pressure at HIGH IDLE	2310 ± 175 kPa (335 ± 25 psi)
	Transmission Lubrication Oil Pressure at LOW IDLE	10 kPa (1.5 psi) minimum
	Transmission Lubrication Oil Pressure at HIGH IDLE	325 kPa (47 psi) minimum(2)
		120 kPa (17 psi) minimum(3)
	Torque Converter Outlet Pressure at HIGH IDLE	380 kPa (55 psi) minimum and 480 kPa (70 psi) maximum(4)
	Torque Converter Inlet Pressure at HIGH IDLE	660 ± 175 kPa (95 ± 25 psi) with oil at normal operating temperature
	Oil Pump Pressure at HIGH IDLE	2310 ± 175 kPa (335 ± 25 psi)

(1)	N = Normal, M = Monitor, A = Action
(2)	The transmission is in THIRD speed and in NEUTRAL position.
(3)	For machines (MDA) that are equipped with a heavy-duty transmission.
(4)	The transmission is in THIRD speed and in FORWARD position. The torque converter is in a stall condition.

Steering System

Reference: Refer to Testing & Adjusting, RENR8672, "Steering System" for more detail on the following tests.

Relief Valve (Steering Cylinder Crossover) - Test and Adjust

Table 21

Status(1)	Description	Specification	Actual	Comments
	Steering Cylinder Crossover Relief Valve Pressure	29100 ± 700 kPa (4220 ± 100 psi)

(1)	N = Normal, M = Monitor, A = Action

Piston Pump (Steering) High Pressure Stall - Test and Adjust

Table 22

Status(1)	Description	Specification	Actual	Comments
	Piston Pump (Steering) High Pressure Stall	24000 ± 350 kPa (3480 ± 50 psi)

(1)	N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Low Pressure Standby - Test and Adjust

Table 23

Status(1)	Description	Specification	Actual	Comments
	Low Pressure Standby	3900 kPa (566 psi)

(1)	N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Margin Pressure - Test and Adjust

Table 24

Status(1)	Description	Specification	Actual	Comments
	Margin Pressure	2400 ± 100 kPa (350 ± 15 psi)

(1)	N = Normal, M = Monitor, A = Action

Relief Valve (Pump Backup) - Test and Adjust

Table 25

Status(1)	Description	Specification	Actual	Comments
	Relief Valve (Pump Backup) - Test	27600 ± 700 kPa (4000 ± 100 psi)

(1)	N = Normal, M = Monitor, A = Action

Steering Neutralizer Valve - Check and Adjust

Table 26

Status(1)	Description	Specification	Actual	Comments
	Pressed Putty Thickness	15.7 mm (0.62 inch)

(1)	N = Normal, M = Monitor, A = Action

Pilot Valve (Steering) Supply Pressure - Test and Adjust

Table 27

Status(1)	Description	Specification	Actual	Comments
	Pilot Valve (Steering) Supply Pressure at pressure tap (3)	3450 ± 250 kPa (500 ± 36 psi)
	Pilot Valve (Steering) Supply Pressure at pressure tap (2)	645 ± 15 kPa (93 ± 2 psi)

(1)	N = Normal, M = Monitor, A = Action

Brake and Hydraulic Fan System

Reference: Refer to Testing & Adjusting, RENR8678, "Electrohydraulic System", and Testing & Adjusting, RENR6215, "Braking System" for more detail on the following tests.

Hydraulic Fan Speed - Test and Adjust

Table 28

Status(1)	Description	Specification	Actual	Comments
	Hydraulic Fan Speed at LOW IDLE(2)	500 + 75 − 25 rpm
	Hydraulic Fan Speed at HIGH IDLE(3)	1250 ± 25 rpm(4)
		1400 ± 25 rpm(5)

(1)	N = Normal, M = Monitor, A = Action
(2)	The fan speed is at low idle. The solenoid valve (demand fan) is connected.
(3)	The hydraulic fan speed is at high idle. The solenoid valve (demand fan) is disconnected.
(4)	for 980H S/N:MHG1-3999
(5)	for 980H S/N:MHG4000-UP

Brake Accumulator - Test and Charge

Table 29

Accumulator Precharge Pressure/Temperature Relationship for the 5500 kPa (800 psi) Service Brake Accumulators
Temperature	Pressure
−7°C (20°F)	5000 kPa (726 psi)
−1°C (30°F)	5105 kPa (741 psi)
4°C (40°F)	5235 kPa (760 psi)
10°C (50°F)	5340 kPa (775 psi)
16°C (60°F)	5420 kPa (787 psi)
21°C (70°F)	5500 kPa (798 psi)
27°C (80°F)	5605 kPa (813 psi)
32°C (90°F)	5735 kPa (832 psi)
38°C (100°F)	5840 kPa (848 psi)
43°C (110°F)	5920 kPa (859 psi)
49°C (120°F)	6000 kPa (871 psi)

Accumulator Charging Valve (Brake) - Test and Adjust

Table 30

Status(1)	Description	Specification	Actual	Comments
	Cutout Pressure	14485 ± 345 kPa (2100 ± 50 psi)
	Cut-in Pressure	11725 ± 345 kPa (1700 ± 50 psi)

(1)	N = Normal, M = Monitor, A = Action

Service Brake System Pressure - Test

Table 31

Status(1)	Description	Specification	Actual	Comments
	Rear Service Brake Pressure (Brake ON)	4310 ± 350 kPa (625 ± 50 psi)
	Front Service Brake Pressure (Brake ON)	4310 ± 350 kPa (625 ± 50 psi)

(1)	N = Normal, M = Monitor, A = Action

S·O·S Samples

Reference: Refer to Operation and Maintenance Manual, SEBU7879, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Engine Oil Sample

Table 32

Status(1)	Description	Obtain	Comments
	Engine Oil Sample

(1)	N = Normal, M = Monitor, A = Action

Engine Coolant Sample

Table 33

Status(1)	Description	Obtain	Comments
	Engine Coolant Sample

(1)	N = Normal, M = Monitor, A = Action

Hydraulic Oil Sample

Table 34

Status(1)	Description	Obtain	Comments
	Hydraulic Oil Sample

(1)	N = Normal, M = Monitor, A = Action

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 35

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 36

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 37

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

(1)	N = Normal, M = Monitor, A = Action