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

Wheel Loader:

938G II (S/N: RTB1-UP; MSC1-UP; CRD1-UP; PHN1-UP; B9Y1-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, SENR9580, "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	Auto-tension
	Difference between the Upper and Lower Radiator Tank Temperatures	6° + 4° - 0°C (43° + 39° - 0°F)
	Jacket Water Inlet Temperature from Cooling System	89° + 3° - 3°C (192° + 37° - 37°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	575 + 125 - 209 kPa (83 + 18 - 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	165 + 235 - 65 kPa (24 + 34 - 9 psi)
	Engine Oil Pressure at HIGH IDLE	320 + 280 - 140 kPa (46 + 41 - 20 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	2340 ± 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	76° to 112°C (169° to 234°F)
	Boost Pressure	132 ± 19.8 kPa (19 ± 2.9 psi)
	Torque Converter Stall Speeds	2085 ± 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)

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

Performance Checks

ReferenceRefer to Testing & Adjusting, RENR6077, "Hydraulic System" and Testing & Adjusting, RENR6072, "Steering System" for more detail on the following test.

Implement Cycle Time

Table 7

Status (1)	Description	Specification	Actual	Comments
	Lift with Empty Bucket (2)	6.1 ± 0.4 seconds
	Dump with Empty Bucket (3)	2.0 ± 0.5 seconds

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	The work tool is in the full TILTBACK position.
( 3 )	The lift arms are in the full RAISE position.

Lift Cylinder - Isolation and Drift Check

Table 8

Status (1)	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes at an Oil temperature of less than 50° C (120° F)	13 mm (0.75 inch)
	Maximum Implement Drift in 2.7 minutes at an Oil temperature of 50° to 65°C (120° to 150°F)	13 mm (0.75 inch)
	Maximum Implement Drift in 1.7 minutes at an Oil temperature of greater than 65°C (149°F)	13 mm (0.75 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Tilt Cylinder - Isolation and Drift Check - 938G Series II Wheel Loader

Table 9

Status (1)	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes at an Oil temperature of less than 50° C (120° F)	19.0 mm (0.75 inch)
	Maximum Implement Drift in 2.7 minutes at an Oil temperature of 50° to 65°C (120° to 150°F)	19.0 mm (0.75 inch)
	Maximum Implement Drift in 1.7 minutes at an Oil temperature of greater than 65°C (150°F)	19.0 mm (0.75 inch)

( 1 )

N = Normal, M = Monitor, A = Action

Steering Time - Check

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	0.3 sec
	Left Turn/Right Turn Time Difference (While the services brakes are engaged)	0.2 sec

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic System

ReferenceRefer to Testing & Adjusting, RENR6077, "Hydraulic System" for more detail on the following test.

Torque Converter Stall and Implement Pump Double Stall - Test

Table 11

Status (1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speeds for Fourth Gear at Torque Converter Oil Temperature of 76° to 112°C (168° to 230°F)	2085 ± 65 rpm
	Torque Converter Stall Speeds for First Gear at Torque Converter Oil Temperature of 76° to 112°C (168° to 230°F)	2015 ± 65 rpm
	Double Stall Speeds for Fourth Gear at Torque Converter Oil Temperature of 76° to 112°C (168° to 230°F)	1705 ± 65 rpm
	Double Stall Speeds for First Gear at Torque Converter Oil Temperature of 76° to 112°C (168° to 230°F)	1705 ± 65 rpm

( 1 )

N = Normal, M = Monitor, A = Action

Pilot System Pressure - Test

Table 12

Status (1)	Description	Specification	Actual	Comments
	Pilot Oil Pressure at HIGH IDLE	3000 ± 400 kPa (435 ± 58 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 at HIGH IDLE	24800 ± 350 kPa (3600 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Line) - Test and Adjust

Table 14

Status (1)	Description	Specification	Actual	Comments
	Line Relief Valve Pressure for Tilt Cylinder at Head End	25800 ± 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)

( 1 )

N = Normal, M = Monitor, A = Action

Ride Control Accumulator - Test and Charge

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)

( 1 )

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

Braking and Hydraulic Fan System

ReferenceRefer to Testing & Adjusting, RENR6075, "Braking System" and Testing & Adjusting, RENR6077, "Hydraulic System" for more detail on the following test.

Brake Accumulator - Test and Charge

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)

Accumulator Charging Valve (Brake) - Test and Adjust

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)

( 1 )

N = Normal, M = Monitor, A = Action

Service Braking System Pressure - Test

Table 18

Status (1)	Description	Specification	Actual	Comments
	Front Service Brake Pressure	8625 ± 350 kPa (1250 ± 50 psi)
	Rear Service Brake Pressure	8625 ± 350 kPa (1250 ± 50 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic Fan Speed - Test and Adjust

Table 19

Status (1)	Description	Specification	Actual	Comments
	Hydraulic Fan Speed at LOW IDLE (2)	500 + 75 - 25 rpm
	Hydraulic Fan Speed at HIGH IDLE (3)	1214 ± 25 rpm

( 1 )	N = Normal, M = Monitor, A = Action
( 2 )	The solenoid valve (hydraulic fan) is connected.
( 3 )	The solenoid valve (hydraulic fan) is disconnected.

Steering System

ReferenceRefer to Testing & Adjusting, RENR6072, "Steering System" for more detail on the following test.

Steering System Pressure (High Pressure Stall) - Test

Table 20

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

( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Low Pressure Standby - Test

Table 21

Status (1)	Description	Specification	Actual	Comments
	Standby Pressure at HIGH IDLE	4700 kPa (680 psi) maximum
	Margin Pressure at HIGH IDLE	2500 kPa (365 psi)

( 1 )

N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Margin Pressure - Test and Adjust

Table 22

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)

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Pump Backup) - Test and Adjust

Table 23

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

( 1 )

N = Normal, M = Monitor, A = Action

Relief Valve (Steering Cylinder Crossover) - Test and Adjust

Table 24

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

( 1 )

N = Normal, M = Monitor, A = Action

Power Train System

ReferenceRefer to Testing & Adjusting, RENR6066, "Power Train" for more detail on the following test.

Transmission Pressures - Test and Adjust

Table 25

Status (1)	Description	Specification	Actual	Comments
	Modulating Valve Pressure for Clutch 1 at HIGH IDLE	1653 ± 70 kPa (240 ± 10 psi)
	Modulating Valve Pressure for Clutch 2 at HIGH IDLE	2246 ± 70 kPa (325 ± 10 psi)
	Modulating Valve Pressure for Clutch 3 at HIGH IDLE	1653 ± 70 kPa (240 ± 10 psi)
	Modulating Valve Pressure for Clutch 4 at HIGH IDLE	2246 ± 70 kPa (325 ± 10 psi)
	Modulating Valve Pressure for Clutch 5 at HIGH IDLE	2246 ± 70 kPa (325 ± 10 psi)
	Modulating Valve Pressure for Clutch 6 at HIGH IDLE	2246 ± 70 kPa (325 ± 10 psi)
	Torque Converter Inlet Pressure at HIGH IDLE	965 kPa (140 psi) Maximum
	Transmission Oil Pump Pressure at HIGH IDLE	2246 ± 70 kPa (326 ± 10 psi)
	Lubrication Oil Pressure at HIGH IDLE	265 ± 50 kPa (38 ± 7 psi)

( 1 )

N = Normal, M = Monitor, A = Action

S·O·S Samples

ReferenceRefer to Operation and Maintenance Manual, SEBU7581, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Engine Oil Sample

Table 26

Status (1)	Description	Obtain	Comments
	Engine Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action

Engine Coolant Sample

Table 27

Status (1)	Description	Obtain	Comments
	Engine Coolant Sample

( 1 )

N = Normal, M = Monitor, A = Action

Hydraulic Oil Sample

Table 28

Status (1)	Description	Obtain	Comments
	Hydraulic Oil Sample

( 1 )

N = Normal, M = Monitor, A = Action

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 29

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 30

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 31

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

( 1 )

N = Normal, M = Monitor, A = Action