988K XE Wheel Loader TA2 Technical Inspection {0372, 0374, 1000, 7000, 753T, 7565} Caterpillar

Wheel Loader

988K XE (S/N: E8X1-UP; EWX1-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.

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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 to prevent stress on battery connections (terminals).
	Battery Test	12.45 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			Refer to Testing and Adjusting, UENR3351, "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)	- -
	Check Freezing Point of Engine Coolant	-
	Conditioner Test of Engine Coolant	-		.
	Check Belt Tension	For used belts - 645 ± 44 N (145 ± 10 lb) For new belts - 801 ± 44 N (180 ± 10 lb)

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

Fuel System Pressure - Test

Table 3

Status(1)	Description	Specification	Actual	Comments
	Fuel Pressure at  (Low Idle)	50 kPa (7 psi)

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

Lubrication System

Table 4

Status(1)	Description	Specification	Actual	Comments
	Engine Oil Pressure at Low Idle	107 kPa (16 psi)
	Engine Oil Pressure at Full Load Speed	278 kPa (40 psi)

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

Basic Engine

Table 5

Status(1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle	750 rpm
	Engine Speed at High Idle	1860 rpm
	Torque Converter Stall Test Engine RPM	-
	Cylinder Cutout Test			Cat® Electronic Technician (Cat ET) Service Tool

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

Air Inlet and Exhaust System

Table 6

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Engine Speed (From Power Train) T&A	-
	Adjusted Boost Pressure	-
	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, M0080709, "988K XE Wheel Loader" for more detail on the following test.

Implement Cycle Time-Check

Table 7

Status(1)	Description	Specification	Actual	Comments
	Lift Raise	8 seconds
	Float Down	3.5 seconds
	Dump	2.2 seconds
	Tilt Back	4.5 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 (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)
	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 for (4) 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 (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).

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).

Hydraulic System

Reference: Refer to Testing & Adjusting, M0080709, "Machine Systems" for more detail on the following test.

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

Table 12

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 13

Status(1)	Description	Specification	Actual	Comments
	Pilot Pressure at High Idle	3800 ± 200 kPa (551 ± 29 psi)

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

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

Table 14

Status(1)	Description	Specification	Actual	Comments
	Cut off Pressure at High Idle	25000 ± 350 kPa (3626 ± 50 psi)

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

Piston Pump Cutoff Pressure (Brake Charging) (Implement, Steering Pilot) - Test and Adjust

Table 15

Status(1)	Description	Specification	Actual	Comments
	Cut off Pressure at High Idle	16000 ± 350 kPa (2321 ± 51 psi)

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

Ride Control Accumulator - Test and Charge - Dual Accumulator

Table 16

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)

Pilot Oil Accumulator - Test

Table 17

Status(1)	Description	Specification	Actual	Comments
	Accumulator Precharge	2000 ± 100 kPa (290 ± 15 psi)

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

Relief Valve (Main) - Test and Adjust

Table 18

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Main Pressure	32800 ± 600 kPa (4757 ± 87 psi)

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

Relief Valve (Pressure Relief for the Lift Cylinder Line) - Test and Adjust

Table 19

Status(1)	Description	Specification	Actual	Comments
	Head End (Lift)	38000 ± 600 kPa (5512 ± 87 psi)
	Rod End (Lift)	34500 ± 600 kPa (5004 ± 87 psi)

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

Relief Valve (Pressure Relief for the Tilt Cylinder Line) - Test and Adjust

Table 20

Status(1)	Description	Specification	Actual	Comments
	Head End (Tilt)	34500 ± 350 kPa (5004 ± 51 psi)
	Rod End (Tilt)	24100 ± 600 kPa (3495 ± 87 psi)

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

Pilot Control Actuator Pressure - Check

Table 21

Status(1)	Description	Specification	Actual	Comments
	Pilot Control Actuator Pressure	3800 ± 300 kPa (551 ± 44 psi)

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

Gear Pump (Axle Oil Cooler) Bypass Relief Pressure - Test and Adjust

Table 22

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure	1034 ± 35 kPa (150 ± 5 psi)
	Pump Flow Rate	117.3 L/min (31 US gpm)

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

Braking and Hydraulic Fan System

Reference: Refer to Testing & Adjusting, M0080709, "Machine Systems" for more detail on the following test.

Brake Accumulator - Test and Charge

Table 23

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 Brake System Pressure - Test

Table 24

Status(1)	Description	Specification	Actual	Comments
	Front Service Brake Pressure	5296 to 5744 kPa (768 to 833 psi)
	Rear Service Brake Pressure	5344 to 5792 kPa (775 to 840 psi)

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

Steering System

Reference: Refer to Testing & Adjusting, M0080709, "Machine Systems" for more detail on the following test.

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

Table 25

Status(1)	Description	Specification	Actual	Comments
	Steering System Pressure at HIGH IDLE	32000 ± 350 kPa (4641 ± 51 psi)

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

Piston Pump (Steering) Margin Pressure - Test and Adjust

Table 26

Status(1)	Description	Specification	Actual	Comments
	Flow Compensator Valve Pressure	1750 to 2200 kPa (254 to 319 psi)

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

Relief Valve (Pump Backup) - Test and Adjust

Table 27

Status(1)	Description	Specification	Actual	Comments
	High Pressure Cutoff (High Idle)	22500 ± 345 kPa (3263 ± 50 psi)

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

Relief Valve (Pilot) (Secondary Steering) - Test and Adjust

Table 28

Status(1)	Description	Specification	Actual	Comments
	Secondary Steering Relief Valve Pressure	1650 kPa (239 psi)

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

Steering Neutralizer Valve - Check and Adjust

Table 29

Status(1)	Description	Specification	Actual	Comments
	Distance between Front and rear frame	12.7 ± 3.0 mm (0.50 ± 0.12 inch)

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

Service Brakes - Test

Table 30

Status(1)	Description	Specification	Actual	Comments
	Allow the oil pressure in the accumulator to reach	16000 ± 345 kPa (2321 ± 50 psi)

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

Parking Brake System Pressure - Test

Table 31

Status(1)	Description	Specification	Actual	Comments
	Accumulator Pressure with Engine Running	13789 ± 345 kPa (2000 ± 50 psi)
	Accumulator Pressure at which the Parking Brake Engages	< 6550 kPa (950 psi)

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

S·O·S Samples

Reference: Refer to Operation and Maintenance Manual, M0085473, "Maintenance Interval Schedule" for more detail on performing S.O.S samples.

Engine Oil Sample

Table 32

Status(1)	Description	Obtain	Comments
	Engine Oil Sample

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

Engine Coolant Sample

Table 33

Status(1)	Description	Obtain	Comments
	Engine Coolant Sample

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

Hydraulic Oil Sample

Table 34

Status(1)	Description	Obtain	Comments
	Hydraulic Oil Sample

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

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 35

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 36

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 37

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

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