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

Wheel Loader

992G (S/N: AZX1-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 ± 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)		Refer to Testing and Adjusting, RENR1309, "Electrical Starting System - Test".
		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

Reference: Testing and Adjusting , RENR1309 , "3508B Engine for Caterpillar Built Machines" for more detail on the following test.

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	900 RPM
	Engine Speed at High Idle	1850 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 seconds
	Move the lift control lever to full LOWER DETENT position (High Idle).(3)	4 seconds
	Move the tilt control lever to full DUMP position (High Idle).(4)	5 seconds
	Move the tilt control lever to full TILT BACK position (High Idle).(5)	3 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
(5)	Record the time to the full DUMP position

Steering Performance Check

Reference: Testing and Adjusting , SENR1373 , "Steering System" for more detail on the following test.

Steering Time - Check and Adjust

Table 6

Status(1)	Description	Specification	Actual	Comments
	Steering time for a full turn (High Idle)	4.4 ± 0.3 seconds
	Steering time for a full turn (Low Idle)	7.4 ± 0.6 seconds

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

Electrohydraulic System

Reference: Testing and Adjusting , SENR1367 , "Electrohydraulic System" for more detail on the following test.

Torque Converter Stall (1FWD) - Test

Table 7

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall (1FWD) (Minimum)(2)(3)	1595 RPM
	Torque Converter Stall (1FWD) (Nominal) (2)(3)	1625 RPM
	Torque Converter Stall (1FWD) (Maximum)(2)(3)	1655 RPM

(1)	N = Normal, M = Monitor, A = Action
(2)	Check the stall speed with the hydraulic fan at maximum speed.
(3)	The position of the boom must be below horizontal to the ground in order for the axle protection mode to be active.

Torque Converter Stall (3FWD) - Test

Table 8

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall (3FWD) (Minimum)(2)	1680 RPM
	Torque Converter Stall (1FWD) (Nominal) (2)	1710 RPM
	Torque Converter Stall (1FWD) (Maximum)(2)	1740 RPM

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

Relief Valve Pressure (Pilot) - Test and Adjust

Table 9

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure (Pilot)	2400 ± 100 kPa (348 ± 15 psi)

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

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

Table 10

Status(1)	Description	Specification	Actual	Comments
	Dead Engine Pilot Pressure at High Idle	1650 ± 150 kPa (239 ± 22 psi)

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

Pilot Control Actuator Pressure - Check

Table 11

Status(1)	Description	Specification	Actual	Comments
	Pilot Control Actuator Pressure	2400 kPa (348 psi)

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

Ride Control Signal Pressure - Check

Table 12

Status(1)	Description	Specification	Actual	Comments
	Ride Control Signal Pressure	2400 ± 100 kPa (348 ± 15 psi)

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

Piston Pump Main Relief Valve Pressure (Fixed Displacement) - Test and Adjust

Table 13

Status(1)	Description	Specification	Actual	Comments
	Main Relief Valve Pressure (Fixed Displacement)	5200 kPa (754 psi)

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

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

Table 14

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure at 1/2 turns of adjustment screw	2930 kPa (425 psi)
	Relief Valve Pressure at 1/4 turns of adjustment screw	1450 kPa (210 psi)
	Relief Valve Pressure at 1/8 turns of adjustment screw	725 kPa (105 psi)

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

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

Table 15

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure at 1/2 turns of adjustment screw	2930 kPa (425 psi)
	Relief Valve Pressure at 1/4 turns of adjustment screw	1450 kPa (210 psi)
	Relief Valve Pressure at 1/8 turns of adjustment screw	725 kPa (105 psi)

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

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

Table 16

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure at 1 turn of adjustment screw	5900 kPa (856 psi)

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

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

Table 17

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure at 1 turn of adjustment screw	11700 kPa (1697 psi)

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

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

Table 18

Status(1)	Description	Specification	Actual	Comments
	Relief Valve Pressure at 1 turn of adjustment screw	11700 kPa (1697 psi)

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

Piston Pump Cutoff Pressure (Variable Displacement) - Test and Adjust

Table 19

Status(1)	Description	Specification	Actual	Comments
	Piston Pump Cut off Pressure (Variable Displacement)	28960 kPa (4200 psi)

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

Piston Pump Backup Relief Valve Pressure (Variable Displacement) - Test and Adjust

Table 20

Status(1)	Description	Specification	Actual	Comments
	Piston Pump Backup Relief Valve Pressure (Variable Displacement)	32750 ± 350 kPa (4750 ± 51 psi)

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

Ride Control Accumulator - Test and Charge

Table 21

Accumulator Precharge Pressure/Temperature Relationship for a Typical 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)

Solenoid Valve (Demand Fan) - Test

Table 22

Status(1)	Description	Specification	Actual	Comments
	Solenoid Valve (Demand Fan)	12700 ± 350 kPa (1842 ± 51 psi)

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

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

Table 23

Status(1)	Description	Specification	Actual	Comments
	Piston Pump Cutoff Pressure (Hydraulic Fan)	12700 ± 350 kPa (1842 ± 51 psi)

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

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

Table 24

Status(1)	Description	Specification	Actual	Comments
	Piston Pump Margin Pressure (Hydraulic Fan)	2000 ± 100 kPa (290 ± 15 psi)

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

Power Train System

Reference: Testing and Adjusting , SENR1347 , "Power Train System" for more detail on the following test.

Torque Converter Impeller Clutch Pressure - Test

Table 25

Status(1)	Description	Specification	Actual	Comments
	Lockup Clutch (if equipped) at Pressure tap (C)	Stabilized pressure with an activated solenoid is 2000 to 2137 kPa (290 to 310 psi) Pressure is less than 170 kPa (25 psi) when the solenoid is not activated
	Torque Converter Inlet at Pressure tap (D)	Maximum pressure with cold oil is 930 kPa (135 psi)
	Impeller Clutch at Pressure tap (F)	Maximum pressure is 2585 ± 205 kPa (375 ± 30 psi). Pressure 2 seconds after a shift is 2050 ± 205 kPa (297 ± 30 psi) Minimum pressure is 620 ± 140 kPa (90 ± 20 psi)
		Maximum pressure is 2482 ± 207 kPa (360 ± 30 psi). Pressure 2 seconds after a shift is 2050 ± 205 kPa (297 ± 30 psi) Minimum pressure is 620 ± 140 kPa (90 ± 20 psi)
	Torque Converter Outlet at Pressure tap (H)	Maximum pressure is 550 kPa (80 psi) Minimum pressure is 415 kPa (60 psi) (These pressures are for a machine in third speed, with activated brakes, with installed axle shafts, and with the converter in a stall condition.)

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

Torque Converter Lockup Clutch Pressure - Test

Table 26

Status(1)	Description	Specification	Actual	Comments
	Lockup Clutch (if equipped) at Pressure tap (C)	Stabilized pressure with an activated solenoid is 2000 kPa (290 psi) to 2137 kPa (310 psi) Pressure is less than 170 kPa (25 psi) when the solenoid is not activated
	Torque Converter Inlet at Pressure tap (D)	Maximum pressure with cold oil is 930 kPa (135 psi)
	Impeller Clutch at Pressure tap (F)	Maximum pressure is 2585 ± 205 kPa (375 ± 30 psi). Pressure 2 seconds after a shift is 2275 ± 205 kPa (330 ± 30 psi) Minimum pressure is 415 ± 205 kPa (60 ± 30 psi)
		Maximum pressure is 2482 ± 207 kPa (360 ± 30 psi) Minimum pressure is 415 ± 205 kPa (60 ± 30 psi)
	Torque Converter Outlet at Pressure tap (H)	Maximum pressure is 550 kPa (80 psi) Minimum pressure is 415 kPa (60 psi) (These pressures are for a machine in third speed, with activated brakes, with installed axle shafts, and with the converter in a stall condition.)

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

Reduced Rimpull Pressure- Test

Table 27

Status(1)	Description	Reduced Rimpull Selection Control Setting	Specification	Actual	Comments
	Reduced Rimpull Pressure	35%	800 to 1350 kPa (116 to 196 psi)
		50%	1095 to 1595 kPa (159 to 231 psi)
		65%	1305 to 1855 kPa (189 ± 269 psi)
		80%	1550 to 2100 kPa (225 to 305 psi)

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

Torque Converter Stall Speed (1FWD) - Test

Table 28

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed (1FWD) (2)	Minimum speed 1595 RPM Nominal speed 1625 RPM Maximum speed 1655 RPM

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

Torque Converter Stall Speed (3FWD) - Test

Table 29

Status(1)	Description	Specification	Actual	Comments
	Torque Converter Stall Speed (3FWD) - Nominal(2)	Minimum speed 1680 RPM Nominal speed 1710 RPM Maximum speed 1740 RPM

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

Transmission Pressures

Table 30

Status(1)	Description	Specification	Actual	Comments
	Oil Pump Pressure at Pressure Tap (A) at Low IDLE	This pressure is identical to speed clutch pressure (P1).
	Oil Pump Pressure at Pressure Tap (A) at High IDLE	This pressure is identical to speed clutch pressure (P1).
	Speed Clutch Initial Pressure (P1) at Pressure Tap (E) at Initial Pressure	The pressure is 530 ± 35 kPa (77 ± 5 psi) when the direction switch is in the Neutral and plug (K) for the load piston is removed.
	Speed Clutch Pressure (P1) at Pressure Tap (E) at 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.
	Speed Clutch Pressure (P1) at Pressure Tap (E) at High IDLE	The pressure is 2515 ± 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 Pressure (P2) at Pressure Tap (G) at LOW IDLE	380 ± 35 kPa (55 ± 5 psi) lower than the speed clutch pressure at pressure tap (E). Plug (K) for the load piston is installed.
	Direction Clutch Pressure (P2) at Pressure Tap (G) at HIGH IDLE	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 at Pressure Tap (J) at HIGH IDLE	172 ± 27 kPa (25 ± 4 psi)

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

Steering System

Reference: Testing and Adjusting , SENR1373 , "Steering System" for more detail on the following test.

Relief Valve (Steering Pilot) - Test and Adjust

Table 31

Status(1)	Description	Specification	Actual	Comments
	Relief Valve (Steering Pilot)	1650 ± 150 kPa (239 ± 22 psi)

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

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

Table 32

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) Low-Pressure Standby - Test and Adjust

Table 33

Status(1)	Description	Specification	Actual	Comments
	Steering Piston Pump (Low-Pressure Standby)	2000 to 5000 kPa (290 to 725 psi)

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

Piston Pump (Steering) Margin Pressure Standby - Test and Adjust

Table 34

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

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

Relief Valve (Steering Cylinder Crossover) - Test and Adjust

Table 35

Status(1)	Description	Specification	Actual	Comments
	Steering Relief Valve (Cylinder Crossover)	31000 ± 700 kPa (4496 ± 102 psi)

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

Relief Valve (Pump Backup) - Test and Adjust

Table 36

Status(1)	Description	Specification	Actual	Comments
	Relief Valve (Pump Backup)	24160 ± 700 kPa (3504 ± 102 psi)

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

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

Table 37

Status(1)	Description	Specification	Actual	Comments
	Relief Valve (Secondary Steering)	17300 ± 700 kPa (2509 ± 102 psi)

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

Braking System

Reference: Testing and Adjusting , SENR1353 , "Braking System" for more detail on the following test.

Piston Pump (Brake) Pressure - Test and Adjust

Table 38

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 39

Status(1)	Description	Specification	Actual	Comments
	Brake Pressure (Brake ON)	4310 ± 350 kPa (625 ± 51 psi)

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

Brake Accumulator - Test and Charge

Table 40

Charging Pressure and temperature Relationship for a Typical 5500 kPa (798 psi) Accumulator
Temperature	Pressure(1)
−7° C (20° F)	5000 kPa (725 psi)
−1° C (30° F)	5105 kPa (740 psi)
4° C (40° F)	5235 kPa (759 psi)
10° C (50° F)	5340 kPa (775 psi)
16° C (60° F)	5420 kPa (786 psi)
21° C (70° F)	5500 kPa (798 psi)
27° C (80° F)	5605 kPa (813 psi)
32° C (90° F)	5735 kPa (832 psi)
38° C (100° F)	5840 kPa (847 psi)
43° C (110° F)	5920 kPa (859 psi)
49° C (120° F)	6000 kPa (870 psi)

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

Parking Brake System Pressure - Test

Table 41

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, SEBU7978, "992G Wheel Loader", "Maintenance Section" for more detail on performing S.O.S samples.

Engine Oil Sample

Table 42

Status(1)	Description	Obtain	Comments
	Engine Oil Sample

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

Engine Coolant Sample

Table 43

Status(1)	Description	Obtain	Comments
	Engine Coolant Sample

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

Hydraulic Oil Sample

Table 44

Status(1)	Description	Obtain	Comments
	Hydraulic Oil Sample

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

Differential & Final Drive Oil Samples (Inboard Final Drives)

Table 45

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 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

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

Transmission/Torque Converter Oil Sample

Table 47

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

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