992K Large Wheel Loader TA2 Technical Inspection {0372, 0374, 1000, 7000, 753T, 7565} Caterpillar

Wheel Loader

992K (S/N: 8801-UP; ZMX1-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 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 ± 1V		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	-		Refer to Operation and Maintenance Manual.
	Difference between the Upper and Lower Radiator Tank Temperatures	-
	Aftercooler Water Outlet Temperature

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

Basic Engine

Table 3

Status(1)	Description	Specification	Actual	Comments
	Engine Speed at Low Idle
	Engine Speed at High Idle
	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 4

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Test 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)	-
	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

Reference: Refer to Testing & Adjusting, M0074763, "Hydraulic Systems" for more detail on the following test.

Implement Cycle Time - Check

Table 5

Status(1)	Description	Specification	Actual	Comments
	Move the lift control lever to full RAISE position (High Idle).(2)	9.8 seconds
	Move the lift control lever to full LOWER DETENT position (High Idle).(3)	3.6 seconds
	Move the tilt control lever to full DUMP position (High Idle).(4)	3.0 seconds

(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

Electrohydraulic System

Reference: Refer to Testing & Adjusting, KENR7579, "Electrohydraulic System" for more detail on the following test.

Tilt Back Double Stall Speed (Electronic Technician) (Center, Right Pumps) - Check

Table 6

Status(1)	Description	Specification	Actual	Comments
	Tilt Back Double Stall Speed	1490 RPM

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

Tilt Back Double Stall Speed with Stall Detection (Electronic Technician) (Center, Right Pumps) - Check

Table 7

Status(1)	Description	Specification	Actual	Comments
	Tilt Double Stall Speed (With Stall Detection)	1520 ± 50 RPM

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

Tilt Back Double Stall Speed without Stall Detection (Electronic Technician) (Center, Right Pumps) - Check

Table 8

Status(1)	Description	Specification	Actual	Comments
	Tilt Double Stall Speed (Without Stall Detection)	1390 ± 50 RPM

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

Lift Double Stall Speed with Stall Detection (Electronic Technician)- Check

Table 9

Status(1)	Description	Specification	Actual	Comments
	Lift Double Stall Speed (With Stall Detection)	1550 ± 50 RPM

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

Torque Converter Stall Speed (First Gear Override) (Electronic Technician) - Test

Table 10

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed (First Gear Override)	1622 ± 20 RPM

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

Torque Converter Stall Speed (Third Gear Override) (Electronic Technician) - Test

Table 11

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed (Third Gear Override)	1715 ± 40 RPM

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

Pressure Reducing Valve (Pilot Oil) - Test and Adjust

Table 12

Status(1)	Description	Specification	Actual	Comments
	Pilot Oil Pressure	3705 ± 605 kPa (537 ± 88 psi)

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

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

Table 13

Status(1)	Description	Specification	Actual	Comments
	Dead Engine Pilot Pressure at High Idle	1580 ± 150 kPa (230 ± 22 psi)

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

Pilot Control Actuator Pressure - Check

Table 14

Status(1)	Description	Specification	Actual	Comments
	Pilot Control Actuator Pressure	3705 ± 605 kPa (537 ± 88 psi)

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

Ride Control Signal Pressure - Check

Table 15

Status(1)	Description	Specification	Actual	Comments
	Ride Control Signal Pressure	3500 ± 150 kPa (508 ± 22 psi)

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

Relief Valve Pressure (Line, Tilt Cylinder Head End) - Test and Adjust

Table 16

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure (High Relief Test)	15500 ± 350 kPa (2248 ± 51 psi)

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

Relief Valve Pressure (Line, Tilt Cylinder Rod End, Left Valve Tilt Back) - Test and Adjust

Table 17

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure (High Relief Test)	15500 ± 350 kPa (2248 ± 51 psi)

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

Relief Valve Pressure (Line, Tilt Cylinder Rod End, Right Valve Tilt Back) - Test and Adjust

Table 18

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure (High Relief Test)	15500 ± 350 kPa (2248 ± 51 psi)

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

Relief Valve Pressure (Line, Lift Cylinder Head End) - Test and Adjust

Table 19

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure (High Relief Test)	38000 ± 350 kPa (5512 ± 51 psi)

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

Relief Valve Pressure (Line, Lift Cylinder Rod End) - Test and Adjust

Table 20

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure (High Relief Test)	38000 ± 350 kPa (5512 ± 51 psi)

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

Ride Control Accumulator - Test and Charge

Table 21

Status(1)	Description	Specification	Actual	Comments
	Accumulator Pressure	5000 ± 70 kPa (725 ± 10 psi)

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

Ride Control Accumulator - Test and Charge

Table 22

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, KENR7586, "Power Train System" for more detail on the following test.

Sequence Valve - Test and Adjust

Table 23

Status(1)	Description	Specification	Actual	Comments
	Pressure at discharge port	22000 ± 150 kPa (3190 ± 22 psi)

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

Torque Converter Impeller Clutch Pressure - Test

Table 24

Status(1)	Description	Specification	Actual	Comments
	Lockup Clutch Hold Pressure (if equipped) at Pressure tap (C)	Minimum pressure is 1965 kPa (285 psi). Maximum pressure is 2100 kPa (305 psi).
	Torque Converter Inlet at Pressure tap (D)	Maximum pressure with cold oil is 930 kPa (135 psi).
	Impeller Clutch (Pedal Released) at Pressure tap (F)	Impeller clutch pressure is 1980 ± 300 kPa (285 ± 44 psi).
	Impeller Clutch (Pedal Depressed) at Pressure tap (F)	Minimum pressure is 356 kPa (50 psi) Maximum pressure is 657 kPa (95 psi).
	Torque Converter Outlet at Pressure tap (H)	Torque converter outlet pressure is 483 ± 68 kPa (70 ± 10 psi).

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

Torque Converter Lockup Clutch Pressure - Test

Table 25

Status(1)	Description	Specification	Actual	Comments
	Lockup Clutch Hold Pressure (if equipped) at Pressure tap (C)	Minimum pressure is 1965 kPa (285 psi). Maximum pressure is 2100 kPa (305 psi).
	Torque Converter Inlet at Pressure tap (D)	Maximum pressure with cold oil is 930 kPa (135 psi).
	Impeller Clutch (Pedal Released) at Pressure tap (F)	Impeller clutch pressure is 1980 ± 300 kPa (285 ± 44 psi).
	Impeller Clutch (Pedal Depressed) at Pressure tap (F)	Minimum pressure is 356 kPa (50 psi) Maximum pressure is 657 kPa (95 psi).
	Torque Converter Outlet at Pressure tap (H)	Torque converter outlet pressure is 70 ± 10 kPa (10 ± 1.5 psi).

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

Reduced Rimpull Pressure- Test

Table 26

Status(1)	Description	Setting	Specification	Actual	Comments
	Reduced Rimpull Pressure	70%	732 to 1588 kPa (106 to 230 psi)
		80%	1007 to 1866 kPa (146 to 270 psi)
		90%	1322 to 2270 kPa (192 to 329 psi)
		100%	1730 to 2970 kPa (251 to 431 psi)

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

Torque Converter Stall Speed (First Gear Override) (Operator Monitor) - Test

Table 27

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed (1FWD) - Nominal(2)	1605 ± 20 RPM

(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

Table 28

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed (3FWD) - Nominal(2)	1730 ± 40 RPM

(1)	N = Normal, M = Monitor, A = Action
(2)	Check the stall speed with the hydraulic fan at maximum speed.

Transmission Pressures - Test and Adjust

Table 29

Transmission Pressure
Pressure	Pressure Tap	Position of Governor Control Lever		Adjustment
		Pressure at Low Idle	Pressure at High Idle
Oil Pump	(A)	This pressure is identical to speed clutch pressure P1.	This pressure is identical to speed clutch pressure P1.	-
Speed Clutch P1 (Initial Pressure)	(E)	The pressure is 530 ± 35 kPa (77 ± 5 psi) when the direction switch is in the NEUTRAL position and plug (K) for the load piston is removed.	-	Add spacers (34) or remove spacers (34).
Speed Clutch P1	(E)	This pressure must not be more than 480 kPa (70 psi) below the pressure at high idle. Plug (K) for the load piston is installed.	This pressure is 2551 ± 140 kPa (365 ± 20 psi) when the direction switch is in FORWARD or in REVERSE and any speed is selected. Plug (K) for the load piston is installed.	-
Direction Clutch P2	(G)	This 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.	This 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.	-
Transmission Lubrication Oil	(J)	-	This pressure is approximately 172 ± 27 kPa (25 ± 4 psi).	-

Steering System

Reference: Refer to Testing & Adjusting, KENR7592, "Steering System" for more detail on the following test.

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

Table 30

Status(1)	Description	Specification	Actual	Comments
	Steering System Pressure at High Idle (High-Pressure Stall)	31000 kPa (4500 psi)

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

Piston Pump (Steering) Margin Pressure - Test and Adjust

Table 31

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

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

Steering Pilot System Pressure - Test and Adjust

Table 32

Status(1)	Description	Specification	Actual	Comments
	Steering Pilot Pump at High Idle	2400 ± 100 kPa (350 ± 20 psi)
	Primary Steering Pump Pilot Pressure at High Idle	1650 ± 150 kPa (240 ± 20 psi)

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

Relief Valve (Steering Cylinder Crossover) - Test and Adjust

Table 33

Status(1)	Description	Specification	Actual	Comments
	Steering Cylinder Crossover Relief Valve Pressure	31000 ± 700 kPa (4500 ± 100 psi)

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

Relief Valve (Pump Backup) - Test and Adjust

Table 34

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)

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

Relief Valve (Secondary Steering) - Test and Adjust - If Equipped

Table 35

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure	17300 ± 700 kPa (2509 ± 100 psi)

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

Steering Neutralizer Valve - Check and Adjust

Table 36

Status(1)	Description	Specification	Actual	Comments
	Right Side Gap (Engine Frame to Non-Engine Frame)	19 ± 3 mm (0.75 ± 0.12 inch)
	Left Side Gap (Engine Frame to Non-Engine Frame)	19 ± 3 mm (0.75 ± 0.12 inch)

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

Steering Time - Check and Adjust

Table 37

Status(1)	Description	Specification	Actual	Comments
	Steering cycle Time	4.4 ± 0.3 seconds

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

Brake and Hydraulic Fan System

Reference: Refer to Testing & Adjusting, KENR7595, "Braking System" for more detail on the following test.

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

Table 38

Status(1)	Description	Specification	Actual	Comments
	Piston Pump Cutoff Pressure (Hydraulic Fan)	24000 ± 350 kPa (3480 ± 50 psi)

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

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

Table 39

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

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

Piston Pump (Brake) Pressure - Test and Adjust

Table 40

Status(1)	Description	Specification	Actual	Comments
	Piston Pump Pressure	13790 ± 345 kPa (2000 ± 50 psi)

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

Service Brake System Pressure - Test

Table 41

Status(1)	Description	Specification	Actual	Comments
	Brake Pressure (Brake ON)	4310 ± 350 kPa (625 ± 50 psi)

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

Brake Accumulator - Test and Charge

Table 42

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)

(1)	Nominal allowable tolerance equals ± 70 kPa (10 psi)

Parking Brake System Pressure - Test

Table 43

Status(1)	Description	Specification	Actual	Comments
	Parking Brake System Pressure	6035 ± 515 kPa (875 ± 75 psi)

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

S·O·S Samples

Reference: Refer to Operation and Maintenance Manual, SEBU8651, "992K Wheel Loader", "Maintenance Section" for more detail on performing S.O.S samples.

Engine Oil Sample

Table 44

Status(1)	Description	Obtain	Comments
	Engine Oil Sample

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

Engine Coolant Sample

Table 45

Status(1)	Description	Obtain	Comments
	Engine Coolant Sample

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

Hydraulic Oil Sample

Table 46

Status(1)	Description	Obtain	Comments
	Hydraulic Oil Sample

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

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 47

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 48

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 49

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

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