924G Wheel Loader TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565} Caterpillar

Wheel Loader:

924G (S/N: WMB1-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	28 ± 1 V		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, RENR2416, "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	14 to 20 mm (0.6 to 0.8 inch)		Alternator and air conditioner belts should deflect 14 to 20 mm (0.6 to 0.8 inch) under 110 N (25 lb) of force.
	Difference between the Upper and Lower Radiator Tank Temperatures	-
	Jacket Water Inlet Temperature from Cooling System	80° to 84°C (176° to 183°F)		Start to open. Full open at 96° C (205° 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 Minimum	26 kPa (4 psi)
	Fuel Pressure Maximum	35 to 55 kPa (5 to 8 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status (1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at HIGH IDLE	300 kPa (44 psi) minimum

( 1 )

N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

Table 5

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Oil Temperature	76° to 112°C (169° to 234°F)
	Torque Converter Stall Speeds	2225 ± 125 RPM
	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.

Performance Checks

ReferenceRefer to Troubleshooting, RENR6423, "Operational Checks (Hydraulic System)" for more detail on the following test.

Cycle Times

Table 6

Status (1)	Description	Specification	Actual	Comments
	Implement Cycle Time for lift control lever at RAISE position	5.0 to 5.5 seconds
	Implement Cycle Time for lift control lever at float to ground position	2.5 to 3.0 seconds
	Implement Cycle Time for lift control lever at TILTBACK position	2.4 to 2.9 seconds
	Implement Cycle Time for lift control lever at DUMP position	1.6 to 1.9 seconds

( 1 )

N = Normal, M = Monitor, A = Action

Drift Check for the Loader Cylinders

Lift Cylinder

Table 7

Status (1)	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes at Hydraulic Oil Temperature of 60° C (140° F)	5 mm (0.20 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Tilt Cylinder

Table 8

Status (1)	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes at Hydraulic Oil Temperature of 60° C (140° F)	5 mm (0.20 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Time - Check

Table 9

Status (1)	Description	Specification	Actual	Comments
	Left Steering Time at LOW IDLE	3.7 seconds
	Right Steering Time at LOW IDLE	3.7 seconds
	Left Steering Time at HIGH IDLE	1.6 seconds
	Right Steering Time at HIGH IDLE	1.6 seconds
	Left Turn/Right Turn Time Difference (While the parking brake is disengaged)	0.3 seconds
	Left Turn/Right Turn Time Difference (While the parking brake is engaged)	0.2 seconds

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic System

ReferenceRefer to Testing & Adjusting, RENR6431, "Hydraulic System" for more detail on the following test.

Piston Pump Pressure - Test and Adjust

Table 10

Status (1)	Description	Specification	Actual	Comments
	Maximum Signal Oil Pressure	23750 ± 350 kPa (3450.0 ± 50.0 psi)
	Maximum Pump Output Pressure	25850 ± 350 kPa (3750.0 ± 50.0 psi)
	Margin Pressure	2000 ± 100 kPa (290 ± 15 psi)
	Pump Standby Pressure	1960 ± 240 kPa (290.0 ± 30.0 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Pilot System Pressure - Test

Table 11

Status (1)	Description	Specification	Actual	Comments
	Steering Pump Maximum Standby Pressure	4300 ± 170 kPa (625 ± 25 psi)
	Pilot System Pressure at HIGH IDLE	2600 ± 170 kPa (375.0 ± 25.0 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Line) - Test and Adjust

Table 12

Status (1)	Description	Specification	Actual	Comments
	Line Relief Valve Pressure for Tilt Cylinder at Head End	12300 ± 200 kPa (1775 ± 29 psi)
	Line Relief Valve Pressure for Tilt Cylinder at Rod End	27550 ± 350 kPa (4000 ± 50 psi)
	Line Relief Valve Pressure for Auxiliary Cylinder for the third function hydraulic arrangement at Head End	22400 ± 350 kPa (3250 ± 50 psi)
	Line Relief Valve Pressure for Auxiliary Cylinder for the third function hydraulic arrangement at Rod End	22400 ± 350 kPa (3250 ± 50 psi)
	Line Relief Valve Pressure for Auxiliary Cylinder for the fourth function hydraulic arrangement at Head End	22400 ± 350 kPa (3250 ± 50 psi)
	Line Relief Valve Pressure for Auxiliary Cylinder for the fourth function hydraulic arrangement at Rod End	22400 ± 350 kPa (3250 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Pilot Oil Accumulator - Test and Charge

Table 13

Status (1)	Description	Specification	Actual	Comments
	Pilot Oil Accumulator Pressure at HIGH IDLE	3100 ± 172 kPa (450 ± 25 psi)
	Pilot Oil Accumulator Pressure (Dead Engine Lower)	860 kPa (125 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Ride Control Accumulator - Test and Charge

Table 14

Status (1)	Description	Specification	Actual	Comments
	Charge Pressure at Ambient Temperature	2446 ± 172 kPa (355.0 ± 25.0 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Braking and Hydraulic Fan System

ReferenceRefer to Testing & Adjusting, RENR6428, "Braking and Hydraulic Fan System" for more detail on the following test.

Fan Speed - Calibrate

Table 15

Status (1)	Description	Specification	Actual	Comments
	Minimum Fan Speed	700 ± 100 RPM
	Maximum Fan Speed	1625 ± 25 RPM

( 1 )

N = Normal, M = Monitor, A = Action

Brake Accumulator - Test and Charge

Table 16

Status (1)	Description	Specification	Actual	Comments
	Cut-in Pressure	9600 ± 345 kPa (1400 ± 50 psi)
	Cut-out Pressure	16000 ± 345 kPa (2300 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Service Braking System Pressure - Test

Table 17

Status (1)	Description	Specification	Actual	Comments
	Front Service Brake Pressure	5600 ± 400 kPa (810 ± 60 psi)
	Rear Service Brake Pressure	5600 ± 400 kPa (810 ± 60 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering System

ReferenceRefer to Testing & Adjusting, RENR6427, "Steering System" for more detail on the following test.

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

Table 18

Status (1)	Description	Specification	Actual	Comments
	Low Pressure Standby Piston Pump Pressure at HIGH IDLE	4065 ± 205 kPa (590 ± 30 psi)

( 1 )

N = Normal, M = Monitor, A = Action

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

Table 19

Status (1)	Description	Specification	Actual	Comments
	High Pressure Stall Piston Pump Pressure at HIGH IDLE	20500 ± 350 kPa (3000 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Steering and Pilot) Margin Pressure - Test and Adjust

Table 20

Status (1)	Description	Specification	Actual	Comments
	Piston Pump Margin Pressure at HIGH IDLE	3600 ± 100 kPa (522 ± 15 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Time - Check

Table 21

Status (1)	Description	Specification	Actual	Comments
	Steering Cycle Time at LOW IDLE	3.7 seconds
	Steering Cycle Time at HIGH IDLE	1.6 seconds
	Steering Cycle Time at LOW IDLE (High Lift)	4.2 seconds
	Steering Cycle Time at HIGH IDLE (High Lift)	1.7 seconds

( 1 )

N = Normal, M = Monitor, A = Action

Metering Pump (HMU) - Test

Table 22

Status (1)	Description	Specification	Actual	Comments
	Metering Pump Pressure at HIGH IDLE	1034 kPa (150 psi) maximum

( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, RENR6425, "Power Train" for more detail on the following test.

Torque Converter Stall - Test

Table 23

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed	2225 ± 125 rpm

( 1 )

N = Normal, M = Monitor, A = Action

Transmission Pressures - Test and Adjust

Table 24

Status (1)	Description	Specification	Actual	Comments
	Transmission Clutch Pressure - Modulating Valve for Clutch 1	2400 ± 170 kPa (350 ± 25 psi)
	Transmission Clutch Pressure - Modulating Valve for Clutch 2
	Transmission Clutch Pressure - Modulating Valve for Clutch 3
	Transmission Clutch Pressure - Modulating Valve for Clutch 4
	Transmission Clutch Pressure - Modulating Valve for Clutch 5
	Transmission Clutch Pressure - Modulating Valve for Clutch 6

( 1 )

N = Normal, M = Monitor, A = Action

Test for the Torque Converter Inlet Pressure

Table 25

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Inlet Pressure at Pressure Tap (P2)	895 kPa (130 psi) maximum

( 1 )

N = Normal, M = Monitor, A = Action

Test for the Torque Converter Outlet Pressure

Table 26

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Outlet Pressure at HIGH IDLE	585 ± 170 kPa (85 ± 25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Test for the Lubrication Oil Pressure

Table 27

Status (1)	Description	Specification	Actual	Comments
	Lubrication Oil Pressure (Minimum) at HIGH IDLE	170 ± 34 kPa (25 ± 5 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Test for the Transmission Oil Pump Pressure

Table 28

Status (1)	Description	Specification	Actual	Comments
	Transmission Oil Pump Pressure at HIGH IDLE	2400 ± 170 kPa (350 ± 25 psi)

( 1 )

N = Normal, M = Monitor, A = Action

S·O·S Samples

ReferenceRefer to Operation and Maintenance Manual, SEBU7645, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Engine Oil Sample

Table 29

Status (1)	Description	Obtain	Comments
	Engine Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action

Engine Coolant Sample

Table 30

Status (1)	Description	Obtain	Comments
	Engine Coolant Sample

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic Oil Sample

Table 31

Status (1)	Description	Obtain	Comments
	Hydraulic Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 32

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 33

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 34

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

( 1 )

N = Normal, M = Monitor, A = Action