- Wheel Loader
- 992K (S/N: KK21-UP; RM21-UP; KK41-UP; RM51-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
Use the following procedure to create an editable electronic copy from SIS web.
- Click format to print.
- Save the document as an HTML format.
- Open the document with Microsoft Word.
Electrical System
Show/hide table
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 to prevent stress on battery connections (terminals). |
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Battery Test |
12.4 VDC or more |
|
Refer to Special Instruction, SEHS7633, "Battery Test Procedure". |
|
Charging System Test |
28 ± 1V |
|
Refer to Special Instruction, REHS0354, "Charging System Troubleshooting". |
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Electric Starting System Test |
12 to 16 V at −23° C (−10° F) to −7° C (19° F) |
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|
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) |
Show/hide table
(1) |
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) |
- |
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Freezing Point of Engine Coolant |
- |
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Conditioner Test of Engine Coolant |
- |
|
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Belt Tension |
- |
|
Refer to Operation and Maintenance Manual. |
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Difference between the Upper and Lower Radiator Tank Temperatures |
- |
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Aftercooler Water Outlet Temperature |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Test for the pressure that is listed on the cap. |
Basic Engine
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Table 3
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Engine Speed at Low Idle |
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Engine Speed at High Idle |
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Torque Converter Stall Test Engine RPM |
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Cylinder Cutout Test |
- |
|
Cat® Electronic Technician (Cat ET Service Tool |
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(1) |
N = Normal, M = Monitor, A = Action |
Air Inlet and Exhaust System
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Table 4
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Stall Test Boost Pressure |
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Cylinder # 1 Exhaust Temperature(2) |
- |
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Cylinder # 2 Exhaust Temperature(2) |
- |
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Cylinder # 3 Exhaust Temperature(2) |
- |
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Cylinder # 4 Exhaust Temperature(2) |
- |
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Cylinder # 5 Exhaust Temperature(2) |
- |
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Cylinder # 6 Exhaust Temperature(2) |
- |
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Cylinder # 7 Exhaust Temperature(2) |
- |
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Cylinder # 8 Exhaust Temperature(2) |
- |
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Show/hide table
(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, M0083603, "Hydraulic Systems" for more detail on the following test.
Implement Cycle Time - Check
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Table 5
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Move the lift control lever to full RAISE position (High Idle).(2) |
9.8 seconds |
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Move the lift control lever to full LOWER DETENT position (High Idle).(3) |
3.6 seconds |
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Move the tilt control lever to full DUMP position (High Idle).(4) |
3.0 seconds |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Record the lift time from ground to the full RAISE position |
(3) |
Record the time from the full RAISE position to the lower kickout position at the ground |
(4) |
Record the time to the full DUMP position |
Steering Performance Checks
Reference: Refer to Testing & Adjusting, M0074624, "Pump Performance (Steering) - Test" for more detail on the following test.
Steering Time - Check and Adjust
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Table 6
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Steering cycle Time |
4.4 ± 0.3 seconds |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Hydraulic System
Reference: Refer to Testing & Adjusting, M0083603, "Testing and Adjusting" for more detail on the following test.
Tilt Back Double Stall Speed (Electronic Technician) (Center, Right Pumps) - Check
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Table 7
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Tilt Back Double Stall Speed |
1490 RPM |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Tilt Back Double Stall Speed with Stall Detection (Electronic Technician) (Center, Right Pumps) - Check
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Table 8
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Tilt Double Stall Speed (With Stall Detection) |
1520 ± 50 RPM |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Tilt Back Double Stall Speed without Stall Detection (Electronic Technician) (Center, Right Pumps) - Check
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Table 9
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Tilt Double Stall Speed (Without Stall Detection) |
1390 ± 50 RPM |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Lift Double Stall Speed with Stall Detection (Electronic Technician)- Check
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Table 10
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Lift Double Stall Speed (With Stall Detection) |
1550 ± 50 RPM |
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|
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(1) |
N = Normal, M = Monitor, A = Action |
Pilot Control Actuator Pressure - Check
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Table 11
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Pilot Control Actuator Pressure |
3705 ± 605 kPa (537 ± 88 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Ride Control Signal Pressure - Check
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Table 12
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Ride Control Signal Pressure |
3500 ± 150 kPa (508 ± 22 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Torque Converter Stall Speed Stall Speed (First Gear Override) (Electronic Technician) - Test
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Table 13
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Stall Speed (First Gear Override) |
1622 ± 20 RPM |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Torque Converter Stall Speed (Third Gear Override) (Electronic Technician) - Test
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Table 14
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Stall Speed (Third Gear Override) |
1715 ± 40 RPM |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Pressure Reducing Valve Pressure for Dead Engine Pilot Supply (Engine OFF) - Test and Adjust
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Table 15
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Dead Engine Pilot Pressure at High Idle |
1580 ± 150 kPa (230 ± 22 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve Pressure (Line, Tilt Cylinder Head End) - Test and Adjust
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Table 16
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Valve Pressure (High Relief Test) |
15500 ± 350 kPa (2248 ± 51 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve Pressure (Line, Tilt Cylinder Rod End, Left Valve Tilt Back) - Test and Adjust
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Table 17
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Valve Pressure (High Relief Test) |
15500 ± 350 kPa (2248 ± 51 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve Pressure (Line, Tilt Cylinder Rod End, Right Valve Tilt Back) - Test and Adjust
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Table 18
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Valve Pressure (High Relief Test) |
15500 ± 350 kPa (2248 ± 51 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve Pressure (Line, Lift Cylinder Head End) - Test and Adjust
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Table 19
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Valve Pressure (High Relief Test) |
38000 ± 350 kPa (5512 ± 51 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve Pressure (Line, Lift Cylinder Rod End) - Test and Adjust
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Table 20
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Valve Pressure (High Relief Test) |
38000 ± 350 kPa (5512 ± 51 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Pressure Reducing Valve (Pilot Oil) - Test and Adjust
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Table 21
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Pilot Oil Pressure |
3705 ± 605 kPa (537 ± 88 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Ride Control Accumulator - Test and Charge
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Table 22
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Accumulator Pressure |
5000 ± 70 kPa (725 ± 10 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Ride Control Accumulator - Test and Charge
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Table 23
Accumulator Precharge Pressure Temperature Relationship for a Typical Ride Control Accumulator with a Precharge of 5000 kPa (725 psi) |
Temperature ° C (° F) |
Pressure Correction kPa (psi) |
−7° C (20° F) |
4530 kPa (657 psi) |
−1° C (30° F) |
4624 kPa (671 psi) |
4° C (40° F) |
4717 kPa (684 psi) |
10° C (50° F) |
4810 kPa (698 psi) |
16° C (60° F) |
4905 kPa (711 psi) |
21° C (70° F) |
5000 kPa (725 psi) |
27° C (80° F) |
5092 kPa (739 psi) |
32° C (90° F) |
5185 kPa (752 psi) |
38° C (100° F) |
5198 kPa (754 psi) |
43° C (110° F) |
5270 kPa (764 psi) |
49° C (120° F) |
5364 kPa (778 psi) |
Power Train System
Reference: Refer to Testing & Adjusting, M0074624, "Power Train - Testing and Adjusting" for more detail on the following test.
Torque Converter Impeller Clutch Pressure - Test
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Table 24
Torque Converter Pressure |
Pressure |
Pressure Tap |
Pressure at High Idle |
Adjustment |
Lockup Clutch Hold Pressure (if equipped) |
(C) |
Minimum pressure is 1965 kPa (285 psi).
Maximum pressure is 2100 kPa (305 psi). |
- |
Torque Converter Inlet |
(D) |
Maximum pressure with cold oil is 930 kPa (135 psi). |
- |
Impeller Clutch (Pedal Released) |
(F) |
Impeller clutch pressure is 1980 ± 300 kPa (287 ± 44 psi). |
- |
Impeller Clutch (Pedal Depressed) |
Minimum pressure is 356 kPa (52 psi)
Maximum pressure is 657 kPa (95 psi). |
- |
Torque Converter Outlet |
(H) |
Torque converter outlet pressure is 70 ± 10 kPa (10 ± 1.5 psi). |
Add spacers (17) or remove spacers (17). |
Torque Converter Lockup Clutch Pressure - Test
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Table 25
Torque Converter Pressure |
Pressure |
Pressure Tap |
Pressure at High Idle |
Adjustment |
Lockup Clutch Hold Pressure (if equipped) |
(C) |
Minimum pressure is 1965 kPa (285 psi).
Maximum pressure is 2100 kPa (305 psi). |
- |
Torque Converter Inlet |
(D) |
Maximum pressure with cold oil is 930 kPa (135 psi). |
- |
Impeller Clutch (Pedal Released) |
(F) |
Impeller clutch pressure is 1980 ± 300 kPa (287 ± 44 psi). |
- |
Impeller Clutch (Pedal Depressed) |
Minimum pressure is 356 kPa (52 psi)
Maximum pressure is 657 kPa (95 psi). |
- |
Torque Converter Outlet |
(H) |
Torque converter outlet pressure is 70 ± 10 kPa (10 ± 1.5 psi). |
Add spacers (17) or remove spacers (17). |
Torque Converter Stall Speed (First Gear Override) (Operator Monitor) - Test
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Table 26
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Stall Speed (1FWD) - Nominal(2) |
1605 ± 20 RPM |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Check the stall speed with the hydraulic fan at maximum speed. |
Torque Converter Stall Speed (Third Gear Override) (Operator Monitor) - Test
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Table 27
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Torque Converter Stall Speed (3FWD) - Nominal(2) |
1730 ± 40 RPM |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
(2) |
Check the stall speed with the hydraulic fan at maximum speed. |
Transmission Pressures - Test and Adjust
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Table 28
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Speed Clutch P1 Pressure (Low Idle) (Initial Pressure) |
530 ± 35 kPa (77 ± 5 psi) when the direction switch is in the NEUTRAL position and plug (K) for the load piston is removed. |
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Speed Clutch P1(Low Idle) |
The pressure must not be more than 480 kPa (70 psi) below the pressure at high idle. Plug (K) for the load piston is installed. |
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Speed Clutch P1 (High Idle) |
The pressure is 2551 ± 140 kPa (365 ± 20 psi) when the direction switch is FORWARD or in REVERSE and any speed is selected. Plug (K) for the load piston is installed. |
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Direction Clutch P2 (Low Idle) (High Idle) |
The pressure is 380 ± 35 kPa (55 ± 5 psi) lower than the speed clutch pressure at pressure tap (E). Plug (K) for the load piston is installed. |
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Transmission Lubrication Oil Pressure (High Idle) |
This pressure is approximately 172 ± 27 kPa (25 ± 4 psi) |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Steering System
Reference: Refer to Testing & Adjusting, M0074624, "Steering System" for more detail on the following test.
Steering System Pressure (High-Pressure Stall) - Test and Adjust
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Table 29
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Steering System Pressure at High Idle (High-Pressure Stall) |
31000 kPa (4500 psi) |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Piston Pump (Steering) Margin Pressure - Test and Adjust
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Table 30
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Piston Pump (Steering) Margin Pressure |
2100 kPa (305 psi) |
|
|
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(1) |
N = Normal, M = Monitor, A = Action |
Steering Pilot System Pressure - Test and Adjust
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Table 31
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Steering Pilot Pump at High Idle |
2400 ± 100 kPa (350 ± 15 psi) |
|
|
|
Primary Steering Pump Pilot Pressure at High Idle |
1650 ± 150 kPa (240 ± 20 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Steering Cylinder Crossover) - Test and Adjust
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Table 32
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Steering Cylinder Crossover Relief Valve Pressure |
31000 ± 700 kPa (4500 ± 100 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Pump Backup) - Test and Adjust
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Table 33
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Valve Pressure |
24160 ± 700 kPa (3500 ± 100 psi) |
|
|
|
Backup Relief Valve Pressure |
34500 ± 700 kPa (5000 ± 100 psi) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Relief Valve (Secondary Steering) - Test and Adjust - If Equipped
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Table 34
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Relief Valve Pressure |
17300 ± 700 kPa (2509 ± 100 psi) |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Steering Neutralizer Valve - Check and Adjust
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Table 35
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Right Side Gap (Engine Frame to Non-Engine Frame |
19 ± 3 mm (0.75 ± 0.12 inch) |
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|
Left Side Gap (Engine Frame to Non-Engine Frame |
19 ± 3 mm (0.75 ± 0.12 inch) |
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|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Braking System
Reference: Refer to Testing & Adjusting, M0074624, "Braking System" for more detail on the following test.
Piston Pump (Brake) Pressure - Test and Adjust
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Table 36
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Piston Pump Pressure |
13790 ± 345 kPa (2000 ± 50 psi) |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Service Brake System Pressure - Test
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Table 37
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Brake Pressure (Brake ON) |
4310 ± 350 kPa (625 ± 50 psi) |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Brake Accumulator - Test and Charge
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Table 38
Charging Pressure and temperature Relationship for a Typical 4820 kPa (700 psi) Accumulator |
Temperature |
Pressure(1) |
−7° C (20° F) |
4350 kPa (631 psi) |
−1° C (30° F) |
4470 kPa (648 psi) |
4° C (40° F) |
4500 kPa (653 psi) |
10° C (50° F) |
4650 kPa (674 psi) |
16° C (60° F) |
4740 kPa (688 psi) |
21° C (70° F) |
4830 kPa (701 psi) |
27° C (80° F) |
4900 kPa (711 psi) |
32° C (90° F) |
5000 kPa (725 psi) |
38° C (100° F) |
5105 kPa (740 psi) |
43° C (110° F) |
5200 kPa (754 psi) |
49° C (120° F) |
5300 kPa (769 psi) |
Show/hide table
(1) |
Nominal allowable tolerance equals ± 70 kPa (10 psi) |
Parking Brake System Pressure - Test
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Table 39
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Parking Brake System Pressure |
6035 ± 515 kPa (875 ± 75 psi) |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Fan System
Reference: Refer to Testing & Adjusting, M0083603, "Braking System" for more detail on the following test.
Piston Pump Cutoff Pressure (Hydraulic Fan) - Test and Adjust
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Table 40
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Cut off Pressure at High Idle |
24000 ± 350 kPa (3480 ± 50 psi) |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Piston Pump Margin Pressure (Hydraulic Fan) - Test and Adjust
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Table 41
Status(1) |
Description |
Specification |
Actual |
Comments |
|
Control Pressure |
4650 to 9050 kPa (674 to 1313 psi) |
|
|
|
Margin Pressure |
2100 ± 100 kPa (305 ± 15 psi) |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
S·O·S Samples
Reference: Refer to Operation and Maintenance Manual, M0074690, "992K Wheel Loader", "Maintenance Section" for more detail on performing S.O.S samples.
Engine Oil Sample
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Table 42
Status(1) |
Description |
Obtain |
Comments |
|
Engine Oil Sample |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Engine Coolant Sample
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Table 43
Status(1) |
Description |
Obtain |
Comments |
|
Engine Coolant Sample |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Hydraulic Oil Sample
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Table 44
Status(1) |
Description |
Obtain |
Comments |
|
Hydraulic Oil Sample |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Differential & Final Drive Oil Samples (Inboard Final Drives)
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Table 45
Status(1) |
Description |
Obtain |
Comments |
|
Front Differential & Final Drive Oil Sample |
|
|
|
Rear Differential & Final Drive Oil Sample |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Differential & Final Drive Oil Samples (Outboard Final Drives)
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Table 46
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 |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |
Transmission/Torque Converter Oil Sample
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Table 47
Status(1) |
Description |
Obtain |
Comments |
|
Transmission/Torque Converter Oil Sample |
|
|
Show/hide table
(1) |
N = Normal, M = Monitor, A = Action |