938G Wheel Loader TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565} Caterpillar

938G Wheel Loader TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565}

Usage:

938G 6WS

Wheel Loader:: 938G (S/N: 6WS1-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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Electrical System

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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, SENR3583, "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)

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N = Normal, M = Monitor, A = Action

Engine

Cooling System

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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	400 ± 44 N·m (295 ± 32 lb ft)
	Difference between the Upper and Lower Radiator Tank Temperatures	5° + 5° - 0°C (41° + 41° - 0°F)
	Jacket Water Inlet Temperature from Cooling System	89° + 3° - 3°C (192° + 37° - 37°F)

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

Fuel System

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Table 3
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Fuel Pressure at HIGH IDLE	400 ± 134 kPa (58 ± 19 psi)

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N = Normal, M = Monitor, A = Action

Lubrication System

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Table 4
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Engine Oil Pressure at LOW IDLE	205 + 395 - 137 kPa (30 + 57 - 20 psi)
	Engine Oil Pressure at HIGH IDLE	320 + 280 - 100 kPa (46 + 41 - 15 psi)

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N = Normal, M = Monitor, A = Action

Basic Engine

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Table 5
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Engine Speed at LOW IDLE	825 ± 10 rpm
	Engine Speed at HIGH IDLE	2363 ± 60 rpm

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N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

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Table 6
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Torque Converter Oil Temperature	82° to 93°C (180° to 199°F)
	Boost Pressure	131 ± 19.7 kPa (19 ± 2.9 psi)
	Torque Converter Stall Speeds	2010 ± 65 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⁾

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

Performance Checks

ReferenceRefer to Testing & Adjusting, SENR6796, "Hydraulic System" and Testing & Adjusting, SENR6790, "Steering System" for more detail on the following test.

Implement Cycle Time - Check

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Table 7
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Implement Cycle Time for lift control lever at RAISE position	6.1 ± 0.5 seconds
	Implement Cycle Time for lift control lever at DUMP position	2.0 ± 0.5 seconds

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N = Normal, M = Monitor, A = Action

Lift and Tilt Cylinder Drift - Check

Lift Cylinder

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Table 8
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes at an Oil temperature of 38° to 49°C (100° to 120°F)	13.0 mm (0.51 inch)
	Maximum Implement Drift in 2.7 minutes at an Oil temperature of 50° to 65°C (122° to 149°F)	13.0 mm (0.51 inch)
	Maximum Implement Drift in 1.7 minutes at an Oil temperature of above 66°C (150°F)	13.0 mm (0.51 inch)

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N = Normal, M = Monitor, A = Action

Tilt Cylinder

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Table 9
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes at an Oil temperature of 38° to 49°C (100° to 120°F)	19.0 mm (0.75 inch)
	Maximum Implement Drift in 2.7 minutes at an Oil temperature of 50° to 65°C (122° to 149°F)	19.0 mm (0.75 inch)
	Maximum Implement Drift in 1.7 minutes at an Oil temperature of above 66°C (150°F)	19.0 mm (0.75 inch)

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N = Normal, M = Monitor, A = Action

Steering Time - Check

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Table 10
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Left Steering Time at HIGH IDLE	2.4 ± 0.3 sec
	Right Steering Time at HIGH IDLE	2.4 ± 0.3 sec
	Left Steering Time at LOW IDLE	4.8 ± 0.5 sec
	Right Steering Time at LOW IDLE	4.8 ± 0.5 sec
	Left Turn/Right Turn Time Difference	0.2 sec

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^( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic System

ReferenceRefer to Testing & Adjusting, SENR6796, "Hydraulic System" for more detail on the following test.

Torque Converter Stall and Implement Pump Double Stall - Test

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Table 11
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Stall Speed in FOURTH SPEED FORWARD for Engine rated at 145 HP	2010 ± 65 rpm
	Stall Speed in FOURTH SPEED FORWARD for Engine rated at 160 HP	2050 ± 65 rpm
	Double Stall Speed in FOURTH SPEED FORWARD for Engine rated at 145 HP	1600 ± 65 rpm
	Double Stall Speed in FOURTH SPEED FORWARD for Engine rated at 160 HP	1660 ± 65 rpm

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^( 1 )

N = Normal, M = Monitor, A = Action

Pilot System Pressure - Test

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Table 12
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Oil Pressure at HIGH IDLE	3000 ± 400 kPa (435 ± 60 psi)

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N = Normal, M = Monitor, A = Action

Relief Valve (Main) - Test and Adjust

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Table 13
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Main Relief Valve Pressure at HIGH IDLE	24800 ± 300 kPa (3600 ± 45 psi)

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N = Normal, M = Monitor, A = Action

Relief Valve (Line) - Test and Adjust

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Table 14
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Line Relief Valve Pressure for Tilt Cylinder at Head End	25900 ± 350 kPa (3750 ± 50 psi)
	Line Relief Valve Pressure for Tilt Cylinder at Rod End	22100 ± 350 kPa (3200 ± 50 psi)
	Line Relief Valve Pressure for Auxiliary Cylinder at Head End	22100 ± 350 kPa (3200 ± 50 psi)
	Line Relief Valve Pressure for Auxiliary Cylinder at Rod End	22100 ± 350 kPa (3200 ± 50 psi)
	Line Relief Valve Pressure for Pin Coupler at Head End	22100 ± 350 kPa (3200 ± 50 psi)
	Line Relief Valve Pressure for Pin Coupler at Rod End	22100 ± 350 kPa (3200 ± 50 psi)

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^( 1 )

N = Normal, M = Monitor, A = Action

Ride Control Accumulator - Test and Charge

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Table 15
Accumulator Precharge Pressure/Temperature Relationship for a Typical 3000 kPa (435 psi) Accumulator
Temperature	Pressure ⁽¹⁾
−7°C (20°F)	2707 kPa (393 psi)
−1°C (30°F)	2766 kPa (401 psi)
4°C (40°F)	2824 kPa (410 psi)
10°C (50°F)	2883 kPa (418 psi)
16°C (60°F)	2941 kPa (427 psi)
21°C (70°F)	3000 kPa (435 psi)
27°C (80°F)	3059 kPa (443 psi)
32°C (90°F)	3117 kPa (452 psi)
38°C (100°F)	3176 kPa (460 psi)
43°C (110°F)	3234 kPa (469 psi)
49°C (120°F)	3293 kPa (477 psi)

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The nominal tolerance is ± 35 kPa (± 5 psi).

Braking and Hydraulic Fan System

ReferenceRefer to Testing & Adjusting, SENR6793, "Braking System" and Testing & Adjusting, SENR6796, "Hydraulic System" for more detail on the following test.

Brake Accumulator - Test and Charge

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Table 16
Accumulator Precharge Pressure/Temperature Relationship for a Typical 6900 kPa (1000 psi) Brake Accumulator
Temperature	Pressure
−7°C (20°F)	6250 kPa (907 psi)
−1°C (30°F)	6380 kPa (926 psi)
4°C (40°F)	6510 kPa (945 psi)
10°C (50°F)	6640 kPa (964 psi)
16°C (60°F)	6770 kPa (983 psi)
21°C (70°F)	6900 kPa (1000 psi)
27°C (80°F)	7030 kPa (1020 psi)
32°C (90°F)	7160 kPa (1039 psi)
38°C (100°F)	7290 kPa (1058 psi)
43°C (110°F)	7420 kPa (1077 psi)
49°C (120°F)	7550 kPa (1096 psi)

Brake Accumulator Charging Valve - Test and Adjust

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Table 17
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Cut-in Pressure	11725 ± 345 kPa (1700 ± 50 psi)
	Cutout Pressure	14485 ± 345 kPa (2100 ± 50 psi)

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N = Normal, M = Monitor, A = Action

Service Braking System Pressure - Test

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Table 18
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Front Service Brake Pressure	6900 ± 350 kPa (1000 ± 50 psi)
	Rear Service Brake Pressure	6900 ± 350 kPa (1000 ± 50 psi)

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N = Normal, M = Monitor, A = Action

Hydraulic Fan Speed - Test and Adjust

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Table 19
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Fan System Pressure at HIGH IDLE	11200 ± 175 kPa (1625 ± 25 psi)
	Fan Speed at HIGH IDLE	1300 ± 25 RPM

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N = Normal, M = Monitor, A = Action

Fan Drive Speed (On Demand Fan) - Test and Adjust

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Table 20
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Minimum Fan Speed	500 ± 20 RPM
	Fan Speed at HIGH IDLE	2350 ± 30 RPM
	Maximum Fan Speed	1300 ± 20 RPM

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N = Normal, M = Monitor, A = Action

Fan Drive Speed (Environmental Machine) - Test and Adjust

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Table 21
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Fan System Pressure at HIGH IDLE	13000 kPa (1885 psi)
	Fan Drive Motor Speed at LOW IDLE	470 ± 20 RPM
	Fan Drive Motor Speed at HIGH IDLE	940 ± 20 RPM

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N = Normal, M = Monitor, A = Action

Steering System

ReferenceRefer to Testing & Adjusting, SENR6790, "Steering System" for more detail on the following test.

Steering System Pressure (High Pressure Stall) - Test

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Table 22
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Steering System Pressure at HIGH IDLE	22800 ± 350 kPa (3305 ± 50 psi)

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^( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Low Pressure Standby - Test

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Table 23
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Standby Pressure at HIGH IDLE	4700 kPa (680 psi) maximum

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N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Margin Pressure - Test

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Table 24
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Margin Pressure at HIGH IDLE	2500 kPa (365 psi)

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N = Normal, M = Monitor, A = Action

Pressure and Flow Compensator Valve (Steering) - Adjust

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Table 25
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Pressure Compensator Valve Pressure	22800 ± 350 kPa (3305 ± 50 psi)
	Flow Compensator Pressure	2500 ± 100 kPa (360 ± 15 psi)

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N = Normal, M = Monitor, A = Action

Relief Valve (Pump Backup) - Test and Adjust

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Table 26
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Pump Backup Relief Valve Pressure at HIGH IDLE	22800 ± 350 kPa (3305 ± 50 psi)

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^( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering Cylinder Crossover) - Test and Adjust

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Table 27
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Steering Cylinder Crossover Relief Valve Pressure at HIGH IDLE	22800 ± 350 kPa (3305 ± 50 psi)

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^( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, SENR6785, "Power Train" for more detail on the following test.

Transmission Pressures - Test and Adjust

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Table 28
Status ⁽¹⁾	Description	Specification	Actual	Comments
	Speed Clutch Pressure (P1) at LOW IDLE	290 ± 70 kPa (42 ± 10 psi) higher than P2 Pressure
	Speed Clutch Pressure (P1) at HIGH IDLE	290 ± 70 kPa (42 ± 10 psi) higher than P2 Pressure
	Direction Clutch Pressure (P2) at LOW IDLE	1896 ± 170 kPa (275 ± 25 psi)
	Direction Clutch Pressure (P2) at HIGH IDLE	1896 ± 170 kPa (275 ± 25 psi)
	Torque Converter Inlet Pressure (P3) at HIGH IDLE	1000 ± 140 kPa (145 ± 20 psi)
	Torque Converter Outlet Pressure at HIGH IDLE	380 kPa (55 psi) minimum
	Torque Converter Outlet Pressure at HIGH IDLE	515 kPa (75 psi) maximum
	Transmission Lubrication Pressure at HIGH IDLE	190 ± 70 kPa (28 ± 10 psi)
	Transmission Oil Pump Pressure at HIGH IDLE	2750 ± 170 kPa (400 ± 25 psi)

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^( 1 )

N = Normal, M = Monitor, A = Action

S·O·S Samples

ReferenceRefer to Operation and Maintenance Manual, SEBU7037, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Engine Oil Sample

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Table 29
Status ⁽¹⁾	Description	Obtain	Comments
	Engine Oil Sample

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N = Normal, M = Monitor, A = Action

Engine Coolant Sample

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Table 30
Status ⁽¹⁾	Description	Obtain	Comments
	Engine Coolant Sample

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N = Normal, M = Monitor, A = Action

Hydraulic Oil Sample

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Table 31
Status ⁽¹⁾	Description	Obtain	Comments
	Hydraulic Oil Sample

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N = Normal, M = Monitor, A = Action

Differential & Final Drive Oil Samples (Inboard Final Drives)

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Table 32
Status ⁽¹⁾	Description	Obtain	Comments
	Front Differential & Final Drive Oil Sample
	Rear Differential & Final Drive Oil Sample

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^( 1 )

N = Normal, M = Monitor, A = Action

Differential & Final Drive Oil Samples (Outboard Final Drives)

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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