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

Wheel Loader

980K (S/N: W7K1-UP; NEP1-UP; GTZ1-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).		Refer to Operation and Maintenance Manual, UENR0946, "Battery or Battery Cable - Inspect/Replace".
	Battery Test	12 VDC		Refer to Testing and Adjusting, UENR0946, "Battery -Test".
	Charging System Test			Refer to Testing and Adjusting, UENR0946 Refer to Special Instruction, REHS0354, "Charging System Test"
	Electric Starting System Test			Refer to Testing and Adjusting, UENR0946, "Electric Starting System Test"

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

Engine

Cooling System

Table 2

Status(1)	Description	Specification	Actual	Comments
	Radiator Pressure Relief (Radiator Cap)(2)			Use 9S-8140 Pressurizing Pump to test the radiator pressure cap. 20 kPa (3 psi) more than the pressure marked on the cap.
	Freezing Point of Engine Coolant
	Conditioner Test of Engine Coolant
	Belt Tension	801 ± 44 N (180 ± 10 lb) for new belts. 645 ± 44 N (145 ± 10 lb) for used belts.		Auto Adjust Belt Tensioner
	Difference between the Upper and Lower Radiator Tank Temperatures

(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	752 kpa (109 psi) + 165 kpa (+24 psi) -290 kpa (-42 psi)

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

Lubrication System

Table 4

Status(1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at low idle	103 kPa (15 psi) to 200 kPa (29 psi)
	Engine Oil Pressure at low idle	179 kPa (26 psi) to 462 kPa (67 psi)

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

Basic Engine

Table 5

Status(1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle	700 ± 10RPM
	Engine Speed at High Idle	2100 ± 10 RPM
	Torque Check Engine Speed	1300 ± 10 RPM
	Boost Pressure At Torque Check Speed	219 ± 33 kPa (32 ± 5 psi)
	Cylinder Cutout Test			Caterpillar Electronic Technician

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

Air Inlet and Exhaust System

Table 6

Status(1)	Description	Specification	Actual	Comments
	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)

(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, KENR6458 for more detail on the following test.

Lift and Tilt Cylinder Drift - Check

Table 7

Status(1)	Description	Specification	Actual	Comments
	Oil Temperature	54° to 70°C (97 ° to 126 °F)
	Lift Cylinder	26 mm (1.1 inch) over 5 minutes
	Tilt Cylinder	37 mm (1.5 inch) over 5 minutes

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

Brake Performance Checks

Reference: Refer to Testing & Adjusting, KENR6455 for more detail on the following test.

Table 8

Status(1)	Description	Specification	Actual	Comments
	Brake Accumulator - Test (Test from OMM)	5500 kPa (798 psi)
	Service Brake Holding Ability Test- Test (Test from OMM)	Front 4310 ± 350 kPa (625 ± 51 psi)
	Parking Brake Holding Ability Test- Test (Test from OMM)	Second Gear Forward High Idle 1900 RPM

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

Steering Performance Checks

Reference: Refer to Testing & Adjusting, KENR6452 for more detail on the following test.

Steering Time - Check

Table 9

Status(1)	Description	Specification	Actual	Comments
	Steering Time	3.0 ± 0.3 seconds

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

Hydraulic System

Reference: Refer to Testing & Adjusting, KENR6458, "Hydraulic System" for more detail on the following test.

Implement Piston Pump Margin Pressure

Table 10

Status(1)	Description	Specification	Actual	Comments
	Implement Piston Pump Margin Pressure	2100 kPa (305 psi)

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

Pilot Pressure to the Main Control Valve

Table 11

Status(1)	Description	Specification	Actual	Comments
	Pilot Pressure to the Main Control Valve	3500 ± 345 kPa (508 ± 50 psi)

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

Load Sensing Relief Valve Pressure

Table 12

Status(1)	Description	Specification	Actual	Comments
	Pressure setting for load sensing signal relief valve	28900 ± 350 kPa (4192 ± 51 psi)

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

Pilot Oil Accumulator - Test

Table 13

Status(1)	Description	Specification	Actual	Comments
	Oil Temperature	60° C (140° F) - 69° C (156° F)
	Accumulator Precharge	1000 ± 50 kPa (145 ± 10 psi)

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

Ride Control Accumulator - Test

Table 14

Status(1)	Description	Specification	Actual	Comments
	Oil Temperature	21° C (70° F)
	Accumulator Precharge High Pressure	4750 kPa (689 psi)
	Accumulator Precharge Low Pressure	1750 kPa (254 psi)

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

Power Train System

Reference: Refer to Testing & Adjusting, KENR6446, "Power Train System" for more detail on the following test.

Tire Pressure

The tire inflation pressure for machines that are shipped from the factory is suitable for shipping only. Always obtain the proper tire inflation pressures for your machine from the tire supplier before placing the machine into operation. The recommended tire inflation pressures for the front tires and for the rear tires will vary for each application.

Proper tire inflation pressure and maintenance of the tire inflation pressure is critical for optimum tire life. The tire inflation pressure should always be obtained from the tire supplier due to changes in the technology of tires, equipment, and job applications.

Reference: Refer to the latest edition of Special Publication, "Caterpillar Performance Handbook" for general information on tire inflation pressure.

Transmission Pressures

Table 15

Transmission Pressures for the 980K Wheel Loaders(1)
Pressure Tap	Specification
(1) Number 1 clutch pressure	2758 ± 140 kPa (400 ± 20 psi)
(2) Number 2 clutch pressure	2758 ± 140 kPa (400 ± 20 psi)
(3) Number 3 clutch pressure	2758 ± 140 kPa (400 ± 20 psi)
(4) Number 4 clutch pressure	2758 ± 140 kPa (400 ± 20 psi)
(5) Number 5 clutch pressure	2310 ± 140 kPa (335 ± 20 psi)
(6) Number 6 clutch pressure	2758 ± 140 kPa (400 ± 20 psi)
(7) Torque converter inlet pressure	550 kPa (80 psi)
(8) Torque converter outlet pressure	415 ± 140 kPa (60 ± 20 psi)
(9) Transmission lubrication pressure	105 kPa (15 psi) (minimum)
(10) Transmission oil pump pressure	2758 ± 70 kPa (400 ± 10 psi)

(1)	Oil pressure at high idle.

Location of Pressure Taps

Illustration 1	g06106459
Transmission clutch pressure taps are located on the right-hand side of the machine. (1) Transmission pressure tap for clutch 1 (reverse clutch) (2) Transmission pressure tap for clutch 2 (forward clutch) (3) Transmission pressure tap for clutch 3 (fourth speed) (4) Transmission pressure tap for clutch 4 (third speed) (5) Transmission pressure tap for clutch 5 (second speed) (6) Transmission pressure tap for clutch 6 (first speed) (7) Torque converter inlet pressure tap (8) Torque converter outlet pressure tap (9) Transmission lubrication pressure tap (10) Transmission pump pressure tap

Torque Converter Lockup Clutch Pressure -Test

Table 16

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Lockup Clutch Pressure -Test	1758 ± 69 kPa (255 ± 10 psi)

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

Steering System

Reference: Refer to Testing & Adjusting, KENR6452, "Steering System" for more detail on the following test.

Piston Pump (Steering) High-Pressure Stall - Test

Table 17

Status(1)	Description	Specification	Actual	Comments
	Piston Pump (Steering) High-Pressure Stall - Test	25500 ± 700 kPa (3699 ± 102 psi)

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

Piston Pump (Steering) Margin Pressure - Test

Table 18

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

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

Steering Pilot System Pressure - Check

Table 19

Status(1)	Description	Specification	Actual	Comments
	Steering Pilot System Pressure-Check	3500 ± 345 kPa (508 ± 50 psi)

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

Relief Valve (Pump Back up) - Test

Table 20

Status(1)	Description	Specification	Actual	Comments
	Relief Valve (Pump Back up) - Test	25500 ± 700 kPa (3699 ± 102 psi)

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

Relief Valve Pressures and Locations

Table 21

Settings for the Line Relief Valves
	Tilt	Auxiliary
Head End	34600 ± 500 kPa (5018 ± 73 psi)	20680 ± 600 kPa (2999 ± 87 psi)
Rod End	34600 ± 500 kPa (5018 ± 73 psi)	20680 ± 600 kPa (2999 ± 87 psi)
Head End (Logging Machines)	34600 ± 500 kPa (5018 ± 73 psi)	20680 ± 600 kPa (2999 ± 87 psi)
Rod End (Logging Machines)	34600 ± 500 kPa (5018 ± 73 psi)	20680 ± 600 kPa (2999 ± 87 psi)

Table 22

Settings for the 980 K HLG Line Relief Valves
	Tilt /Auxiliary	Lift
Head End (High Lift Grapple)	26000 ± 500 kPa (3771 ± 73 psi)	-
Rod End (High Lift Grapple)	26000 ± 500 kPa (3771 ± 73 psi)	26000 ± 500 kPa (3771 ± 73 psi)

Steering Cylinder Relief Valve - Test

Table 23

Status(1)	Description	Specification	Actual	Comments
	Steering Cylinder Relief Valve - Test	30600 ± 400 kPa (4438 ± 58 psi)

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

Brake and Hydraulic Fan System

Reference: Refer to Testing & Adjusting, KENR6455 for more detail on the following test.

Brake Accumulator Precharging Pressure

Table 24

980K Brake Accumulator charging valve pressure
Date	Equipment ID Code
Pump Pressure	Setting	Actual
Cut-In pressure	12760 ± 345 kPa (1851 ± 50 psi)
Cut-Out pressure	15170 ± 345 kPa (2200 ± 50 psi)

Service Brake System Pressure - Test

Table 25

Status(1)	Description	Specification	Actual	Comments
	Service brake valve(2)	4310 ± 350 kPa (625 ± 51 psi)

(1)	N = Normal, M = Monitor, A = Action
(2)	For both Front and Rear Brakes

Service Brake Wear Indicator

Table 26

Status(1)	Description	Specification	Actual	Comments
	Right Front Indicator Depth	1.05 mm (0.04 inch)
	Left Front Indicator Depth	1.05 mm (0.04 inch)
	Right Rear Indicator Depth	1.05 mm (0.04 inch)
	Left Rear Indicator Depth	1.05 mm (0.04 inch)

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

Hydraulic Fan (If Equipped)

Table 27

Status(1)	Description	Specification	Actual	Comments
	Max Fan Speed	1460 ± 50 RPM
	Minimum Fan Speed	525 ± 50 RPM
	Margin Pressure (High Idle)	1200 ± 100 kPa (174 ± 15 psi)
	High-Pressure cut off (High Idle)	19000 ± 700 kPa (2756 ± 102 psi)

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

S·O·S Samples

Reference: Refer to Operation and Maintenance Manual, M0067704, "Maintenance Interval Schedule" for more detail on performing S.0.S samples.

Engine Oil Sample

Table 28

Status(1)	Description	Obtain	Comments
	Engine Oil Sample

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

Engine Coolant Sample

Table 29

Status(1)	Description	Obtain	Comments
	Engine Coolant Sample

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

Hydraulic Oil Sample

Table 30

Status(1)	Description	Obtain	Comments
	Hydraulic Oil Sample

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

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 31

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 32

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 33

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

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