990K Wheel Loader TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar

Wheel Loader

990K (S/N: DJK1-UP; A9P1-UP; M9P1-UP; K9X1-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

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 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
	Difference between the Upper and Lower Radiator Tank Temperatures
	Jacket Water Inlet Temperature from Cooling System

(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 System Pressure at LOW IDLE	650 ± 50 kPa (94 ± 7 psi)
	Fuel System Pressure at HIGH IDLE	705 ± 50 kPa (102 ± 7 psi)

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

Basic Engine

Table 4

Status(1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle	700 ± 10 RPM
	Engine Speed at High Idle	2010 ± 40 RPM

(1)	N = Normal, M = Monitor, A = Action2010

Lubrication System

Table 5

Status(1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at LOW IDLE	200 kPa (29 psi)
	Engine Oil Pressure	345 kPa (50 psi)

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

Air Inlet and Exhaust System

Table 6

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Oil Temperature	60° to 121°C (140° to 219°F)
	Torque Converter Stall Speed	1990 +10 - 65 rpm
	Torque Converter Double Stall Oil Temperature	93° ± 17°C (199° ± 30°F)
	Torque Converter Double Stall Speed	1428 ± 100 rpm
	Cylinder # 1 Exhaust Temperature(2)
	Cylinder # 2 Exhaust Temperature ***#i05833736/d28266e1012***
	Cylinder # 3 Exhaust Temperature ***#i05833736/d28266e1012***
	Cylinder # 4 Exhaust Temperature ***#i05833736/d28266e1012***
	Cylinder # 5 Exhaust Temperature ***#i05833736/d28266e1012***
	Cylinder # 6 Exhaust Temperature ***#i05833736/d28266e1012***
	Cylinder # 7 Exhaust Temperature ***#i05833736/d28266e1012***
	Cylinder # 8 Exhaust Temperature ***#i05833736/d28266e1012***

(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, UENR3849, "Machine Systems" for more detail on the following test.

Implement Cycle Time - Check

Table 7

Status(1)	Description	Specification	Actual	Comments
	Lift Cycle Time	8.4 ± 0.5 seconds
	Rack Cycle Time	4.4 ± 0.3 seconds
	Dump Cycle Time	2.4 ± 0.2 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 without Ride Control	20 mm (0.78 inch)
	Maximum Implement Drift in 2.5 minutes(3) for Rod Movement of Lift Cylinder without Ride Control	20 mm (0.78 inch)
	Maximum Implement Drift in 1.7 minutes(4) for Rod Movement of Lift Cylinder without Ride Control	20 mm (0.78 inch)
	Maximum Implement Drift in 5.0 minutes ***#i05833736/d28266e1406*** for Rod Movement of Lift Cylinder with Ride Control	25 mm (1 inch)
	Maximum Implement Drift in 2.5 minutes ***#i05833736/d28266e1451*** for Rod Movement of Lift Cylinder with Ride Control	25 mm (1 inch)
	Maximum Implement Drift in 1.7 minutes ***#i05833736/d28266e1496*** for Rod Movement of Lift Cylinder with Ride Control	25 mm (1 inch)
	Maximum Implement Drift in 5.0 minutes ***#i05833736/d28266e1406*** for Rod Movement of Tilt Cylinder	15 mm (0.6 inch)
	Maximum Implement Drift in 2.5 minutes ***#i05833736/d28266e1451*** for Rod Movement of Tilt Cylinder	15 mm (0.6 inch)
	Maximum Implement Drift in 1.7 minutes ***#i05833736/d28266e1496*** for Rod Movement of Tilt Cylinder	15 mm (0.6 inch)

(1)	N = Normal, M = Monitor, A = Action
(2)	Oil temperature between 40° C (104° F) to 49° C (120° F).
(3)	Oil temperature between 50° C (122° F) to 59° C (138° F).
(4)	Oil temperature between 60° C (140° F) to 69° C (156° F).

Lift Cylinder - Isolation and Drift Check

Table 9

Status(1)	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes(2) for Rod Movement of Lift Cylinder without Ride Control	20 mm (0.78 inch)
	Maximum Implement Drift in 2.5 minutes(3) for Rod Movement of Lift Cylinder without Ride Control	20 mm (0.78 inch)
	Maximum Implement Drift in 1.7 minutes(4) for Rod Movement of Lift Cylinder without Ride Control	20 mm (0.78 inch)
	Maximum Implement Drift in 5.0 minutes ***#i05833736/d28266e1774*** for Rod Movement of Lift Cylinder with Ride Control	25 mm (1 inch)
	Maximum Implement Drift in 2.5 minutes ***#i05833736/d28266e1819*** for Rod Movement of Lift Cylinder with Ride Control	25 mm (1 inch)
	Maximum Implement Drift in 1.7 minutes ***#i05833736/d28266e1864*** for Rod Movement of Lift Cylinder with Ride Control	25 mm (1 inch)

(1)	N = Normal, M = Monitor, A = Action
(2)	Oil temperature between 40° C (104° F) to 49° C (120° F).
(3)	Oil temperature between 50° C (122° F) to 59° C (138° F).
(4)	Oil temperature between 60° C (140° F) to 69° C (156° F).

Tilt Cylinder - Isolation and Drift Check

Table 10

Status(1)	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes(2) for Rod Movement of Tilt Cylinder	15 mm (0.6 inch)
	Maximum Implement Drift in 2.5 minutes(3) for Rod Movement of Tilt Cylinder	15 mm (0.6 inch)
	Maximum Implement Drift in 1.7 minutes(4) for Rod Movement of Tilt Cylinder	15 mm (0.6 inch)

(1)	N = Normal, M = Monitor, A = Action
(2)	Oil temperature between 40° C (104° F) to 49° C (120° F).
(3)	Oil temperature between 50° C (122° F) to 59° C (138° F).
(4)	Oil temperature between 60° C (140° F) to 69° C (156° F).

Ride Control Valve - Isolation and Drift Check

Table 11

Status(1)	Description	Specification	Actual	Comments
	Maximum Implement Drift in 5.0 minutes(2) for Rod Movement of Lift Cylinder with Ride Control	25 mm (1 inch)
	Maximum Implement Drift in 2.5 minutes(3) for Rod Movement of Lift Cylinder with Ride Control	25 mm (1 inch)
	Maximum Implement Drift in 1.7 minutes(4) for Rod Movement of Lift Cylinder with Ride Control	25 mm (1 inch)

(1)	N = Normal, M = Monitor, A = Action
(2)	Oil temperature between 40° C (104° F) to 49° C (120° F).
(3)	Oil temperature between 50° C (122° F) to 59° C (138° F).
(4)	Oil temperature between 60° C (140° F) to 69° C (156° F).

Brake Performance Checks

Reference: Refer to Operation and Maintenance Manual, SEBU9121, "Braking System - Test" for more detail on the following test.

Table 12

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, UENR3849, "Machine Systems" for more detail on the following test.

Steering Time - Check and Adjust

Table 13

Status(1)	Description	Specification	Actual	Comments
	Left/Right Steering Time for a Full Turn from Stop to Stop (LOW IDLE)	7.4 ± 0.6 seconds
	Left/Right Steering Time for a Full Turn from Stop to Stop (HIGH IDLE)	3.7 ± 0.3 seconds
	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

Reference: Refer to Testing & Adjusting, UENR3849, "Machine Systems" for more detail on the following test.

Pressure Reducing Valve Pressure for Dead Engine Pilot Supply (Engine OFF) - Test and Adjust

Table 14

Status(1)	Description	Specification	Actual	Comments
	Dead Engine Pilot Pressure at High Idle	1580 ± 300 kPa (230 ± 45 psi)

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

Pilot Pressure (Pressure Reducing Valve) - Test and Adjust

Table 15

Status(1)	Description	Specification	Actual	Comments
	Implement Pilot Pressure at High Idle	3500 ± 345 kPa (500 ± 50 psi)

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

Piston Pump Cutoff Pressure (Hydraulic Fan) - Test and Adjust

Table 16

Status(1)	Description	Specification	Actual	Comments
	Cut off Pressure at High Idle	27700 ± 500 kPa (4017.6 ± 73 psi)

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

Ride Control Accumulator - Test and Charge - Dual Accumulator

Table 17

Accumulator Precharge Pressure Temperature Relationship for a Typical Ride Control Accumulator
Temperature ° C (° F)	Pressure Correction kPa (psi)
−7° C (20° F)	−270 kPa (−39 psi)
−1° C (30° F)	−215 kPa (−31 psi)
4° C (40° F)	−160 kPa (−23 psi)
10° C (50° F)	−105 kPa (−15 psi)
16° C (60° F)	−50 kPa (−7 psi)
21° C (70° F)	0 kPa (0 psi)
27° C (80° F)	60 kPa (8 psi)
32° C (90° F)	115 kPa (16 psi)
38° C (100° F)	170 kPa (25 psi)
43° C (110° F)	225 kPa (32 psi)
49° C (120° F)	280 kPa (40 psi)

Braking and Hydraulic Fan System

Reference: Refer to Testing & Adjusting, UENR3849, "Machine Systems" for more detail on the following test.

Brake Accumulator - Test and Charge

Table 18

Status(1)	Description	Specification	Actual	Comments
	Brake Accumulator Pressure	15650 to 16350 kPa (2270 to 2371 psi)

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

Service Braking System Pressure - Test

Table 19

Status(1)	Description	Specification	Actual	Comments
	Front Service Brake Pressure	4310 ± 350 kPa (625 ± 50 psi)
	Rear Service Brake Pressure	4520 ± 380 kPa (656 ± 55 psi)

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

Steering System

Reference: Refer to Testing & Adjusting, UENR3849, "Machine Systems" for more detail on the following test.

Pump Performance (Steering) - Test

Table 20

Status(1)	Description	Specification	Actual	Comments
	Steering Time	3.7 ± 0.3 seconds

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

Steering System Pressure (High Pressure Stall) - Test and Adjust

Table 21

Status(1)	Description	Specification	Actual	Comments
	Steering System Pressure at HIGH IDLE	31000 ± 750 kPa (4500 ± 110 psi)

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

Piston Pump (Steering) Margin Pressure - Test and Adjust

Table 22

Status(1)	Description	Specification	Actual	Comments
	Flow Compensator Valve Pressure	2100 ± 100 kPa (305 ± 15 psi)

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

Relief Valve (Steering Cylinder Crossover) - Test and Adjust

Table 23

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure	34500 ± 700 kPa (5004 ± 102 psi)

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

Relief Valve (Pump Backup) - Test and Adjust

Table 24

Status(1)	Description	Specification	Actual	Comments
	Steering Backup Relief Valve Pressure	34500 ± 700 kPa (5004 ± 102 psi)

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

Relief Valve (Secondary Steering) - Test and Adjust

Table 25

Status(1)	Description	Specification	Actual	Comments
	Secondary Steering Relief Valve Pressure	17300 ± 700 kPa (2510 ± 100 psi)

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

Power Train System

Reference: Refer to Testing & Adjusting, UENR3849, "Machine Systems" for more detail on the following test.

Torque Converter Impeller Clutch Pressure - Test

Table 26

Status(1)	Description	Specification	Actual	Comments
	Lockup Clutch Pressure at Pressure Tap (A)	2550 ± 140 kPa (370 ± 20 psi)(2)
	Torque Converter Inlet Pressure at Pressure Tap (C)	930 kPa (135 psi)
	Impeller Clutch Pressure at Pressure Tap (D)	1950 kPa (285 psi)(3)
	Maximum Torque Converter Outlet at Pressure Tap (G)	550 kPa (80 psi)(4)
	Minimum Torque Converter Outlet at Pressure Tap (G)	415 kPa (60 psi) ***#i05833736/d28266e4125***

(1)	N = Normal, M = Monitor, A = Action
(2)	Pressure is less than 170 kPa (25 psi) when the solenoid is not activated.
(3)	Pressure with the left brake pedal fully depressed is 220 ± 150 kPa (32 ± 22 psi).
(4)	These pressures are for a machine in third speed, with activated brakes, with installed axle shafts, and with the converter in a stall condition.)

Torque Converter Stall - Test

Table 27

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed	1990 +10 - 65 rpm
	Torque Convertor Double Stall Speed	1428 ± 100 rpm

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

Torque Converter Lockup Clutch Pressure - Test

Table 28

Status(1)	Description	Specification	Actual	Comments
	Lockup Clutch Pressure at Pressure Tap (A)	2550 ± 140 kPa (370 ± 20 psi)(2)
	Torque Converter Inlet Pressure at Pressure Tap (C)	930 kPa (135 psi)
	Impeller Clutch Pressure at Pressure Tap (D)	2500 ± 140 kPa (370 ± 20 psi)(3)
	Maximum Torque Converter Outlet at Pressure Tap (G)	550 kPa (80 psi)(4)
	Minimum Torque Converter Outlet at Pressure Tap (G)	415 kPa (60 psi) ***#i05833736/d28266e4460***

(1)	N = Normal, M = Monitor, A = Action
(2)	Pressure is less than 170 kPa (25 psi) when the solenoid is not activated.
(3)	Pressure with the left brake pedal fully depressed is 130 kPa (19 psi) minimum and 400 kPa (58 psi) maximum.
(4)	These pressures are for a machine in third speed, with activated brakes, with installed axle shafts, and with the converter in a stall condition.)

Transmission Pressures - Test and Adjust

Table 29

Status(1)	Description	Specification	Actual	Comments
	Speed Clutch Initial Pressure (P1) at Pressure Tap (F) at LOW IDLE	530 ± 20 kPa (76 ± 3 psi) Maximum
	Speed Clutch Pressure (P1) at Pressure Tap (F) at HIGH IDLE	2800 ± 140 kPa (406 ± 20 psi)
	Speed Clutch Pressure (P1) at Pressure Tap (F) at LOW IDLE	must not be more than 350 kPa (50 psi) below the pressure at high idle
	Direction Clutch Pressure (P2) at Pressure Tap (J)	380 ± 35 kPa (55 ± 5 psi) lower than the speed clutch pressure at pressure tap (F)
	Transmission Lubrication Oil Pressure at HIGH IDLE	135 kPa (20 psi) minimum

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

S·O·S Samples

Reference: Refer to Operation and Maintenance Manual, SEBU9121, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Engine Oil Sample

Table 30

Status(1)	Description	Obtain	Comments
	Engine Oil Sample

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

Engine Coolant Sample

Table 31

Status(1)	Description	Obtain	Comments
	Engine Coolant Sample

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

Hydraulic Oil Sample

Table 32

Status(1)	Description	Obtain	Comments
	Hydraulic Oil Sample

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

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 33

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 34

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 35

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

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