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966H and 972H Wheel Loader TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar


966H and 972H Wheel Loader TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565}

Usage:

966H A6D
Wheel Loader
966H (S/N: A6D1-UP; RYF1-UP; A6G1-UP; A6J1-UP; TAL1-UP)
972H (S/N: GTA1-UP; LCC1-UP; A7D1-UP; A7G1-UP; A7J1-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

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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, SEBU7887, "Battery or Battery Cable - Inspect/Replace" 
  Battery Test  12 VDC    Refer to Testing and Adjusting, SENR9888, "Battery - Test". 
  Charging System Test      Refer to Testing and Adjusting, SENR9888, "Battery - Test".
Refer to Troubleshooting, SENR1394 , "Charging System"
Refer to Special Instruction, REHS0354 
  Electric Starting System Test      Refer to Testing and Adjusting, SENR9888 
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(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)      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  534 N (120 lb) for new belts.
400 N (90 lb) for used belts. 		   Auto Adjust Belt Tensioner 
  Difference between the Upper and Lower Radiator Tank Temperatures       
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(1) N = Normal, M = Monitor, A = Action
(2) Test for the pressure that is listed on the cap.

Fuel System

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Table 3
Status(1)  Description  Specification  Actual  Comments 
  Maximum Fuel Pressure of the High-Pressure Fuel System  207 MPa (30022 psi)     
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(1) N = Normal, M = Monitor, A = Action

Lubrication System

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Table 4
Status(1)  Description  Specification  Actual  Comments 
  At rated engine operating conditions of 110° C (230° F)  275 kPa (40 psi)     
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(1) N = Normal, M = Monitor, A = Action

Basic Engine

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Table 5
Status(1)  Description  Specification  Actual  Comments 
  Engine Speed at Low Idle  825 ± 10 RPM     
  Engine Speed at High Idle  2270 ± 40 RPM     
  Torque Converter Stall Test Engine RPM  1400 ± 10 RPM     
  Cylinder Cutout Test      Caterpillar Electronic Technician 
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(1) N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

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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)       
  Cylinder # 7 Exhaust Temperature(2)       
  Cylinder # 8 Exhaust Temperature(2)       
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(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, RENR8858 for more detail on the following test.

Implement Cycle Time - Check

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Table 7
Status(1)  Description  Specification  Actual  Comments 
  966H Lift Raise  6.5 ± 0.5 sec     
  972H Lift Raise  6.5 ± 0.5 sec     
  966H Lift Lower  3.5 ± 0.5 sec     
  972H Lift Lower  3.7 ± 0.5 sec     
  966H Float  2.8 ± 0.5 sec     
  972H Float  2.8 ± 0.5 sec     
  966H Dump  2.7 ± 0.5 sec     
  972H Dump  3.3 ± 0.5 sec     
  966H Tilt Back  2.5 ± 0.5 sec     
  972H Tilt Back  3.4 ± 0.5 sec     
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(1) N = Normal, M = Monitor, A = Action

Lift and Tilt Cylinder Drift - Check for 966H

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Table 8
Status(1)  Description  Specification  Actual  Comments 
  Oil Temperature at 38° to 49° C (100° to 120° F)  5.0 minutes     
  Oil Temperature at 50° to 65° C (122° to 149° F)  2.7 minutes     
  Oil Temperature at 66° C (150° F) or more  1.7 minutes     
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(1) N = Normal, M = Monitor, A = Action

Lift and Tilt Cylinder Drift - Check for 972H

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Table 9
Status(1)  Description  Specification  Actual  Comments 
  Oil Temperature at 50° to 65° C (122° to 149° F)  2.7 minutes     
  Oil Temperature at 66° C (150° F) or more  1.7 minutes     
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(1) N = Normal, M = Monitor, A = Action

Steering Performance Checks

Reference: Refer to Testing & Adjusting, RENR8852 for more detail on the following test.

Steering Time - Check

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Table 10
Status(1)  Description  Specification  Actual  Comments 
  Left Steering Time (Command Control Steering)  2.9 ± 0.5 seconds     
  Right Steering Time (Command Control Steering)  2.9 ± 0.5 seconds     
  Left Steering Time (HMU System) at high idle  More than 2.9 ± 0.5 seconds     
  Right Steering Time (HMU System) at high idle  2.9 ± 0.5 seconds     
  Left Steering Time (HMU System) at low idle  4.9 ± 0.5 seconds     
  Right Steering Time (HMU System) at low idle  4.9 ± 0.5 seconds     
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(1) N = Normal, M = Monitor, A = Action

Hydraulic System

Reference: Refer to Testing & Adjusting, RENR8858, "Hydraulic System" for more detail on the following test.

Pilot Pressure to the Main Control Valve

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Table 11
Status(1)  Description  Specification  Actual  Comments 
  Pilot Pressure to the Main Control Valve  3515 ± 345 kPa (510 ± 50 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Load Sensing Signal) - Test and Adjust

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Table 12
Status(1)  Description  Specification  Actual  Comments 
  Standard machine  31000 ± 690 kPa (4496 ± 100 psi)     
  Logging machine  31000 ± 690 kPa (4496 ± 100 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Line) - Test and Adjust

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Table 13
Status(1)  Description  Specification  Actual  Comments 
  Standard machine  31000 ± 690 kPa (4496 ± 100 psi)     
  Logging machine  31000 ± 690 kPa (4496 ± 100 psi)     
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(1) N = Normal, M = Monitor, A = Action

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Table 14
Status(1)  Description  Specification  Actual  Comments 
Tilt Auxiliary
  Head End  34450 ± 350 kPa (4997 ± 51 psi)  -     
  Rod End  34450 ± 350 kPa (4997 ± 51 psi)  -     
  Head End (Logging)  38750 ± 350 kPa (5620 ± 51 psi)  20680 ± 350 kPa (2999 ± 51 psi)     
  Rod End (Logging)  34450 ± 350 kPa (4997 ± 51 psi)  20680 ± 350 kPa (2999 ± 51 psi)     
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(1) N = Normal, M = Monitor, A = Action

Pilot Oil Accumulator (Dead Engine, Lift Arm Lower) - Test and Charge

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Table 15
Status(1)  Description  Specification  Actual  Comments 
  Pilot Oil Accumulator (Dead Engine, Lift Arm Lower) - Test and Charge  3515 ± 345 kPa (510 ± 50 psi)     
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(1) N = Normal, M = Monitor, A = Action

Ride Control Accumulator - Test and Charge

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Table 16
Status(1)  Description  Specification  Actual  Comments 
  Ride Control Accumulator - Test and Charge  2960 kPa (429 psi)     
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(1) N = Normal, M = Monitor, A = Action

Power Train System

Reference: Refer to Testing & Adjusting, RENR8846, "Power Train System" for more detail on the following test.

Torque Converter Stall - Test

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Table 17
Status(1)  Description  Specification  Actual  Comments 
  Torque Converter Stall - Test  2185 ± 65 RPM     
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(1) N = Normal, M = Monitor, A = Action

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 Test and Adjust

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Table 18
Transmission Pressures for the 966H and 972H Wheel Loaders(1) 
Pressure Tap Number  Description  Specification 
1  Transmission pressure tap for clutch 1  2758 ± 140 kPa (400 ± 20 psi) 
2  Transmission pressure tap for clutch 2  2758 ± 140 kPa (400 ± 20 psi) 
3  Transmission pressure tap for clutch 3  2758 ± 140 kPa (400 ± 20 psi) 
4  Transmission pressure tap for clutch 4  2758 ± 140 kPa (400 ± 20 psi) 
5  Transmission pressure tap for clutch 5  2310 ± 140 kPa (335 ± 20 psi) 
6  Transmission pressure tap for clutch 6  2758 ± 140 kPa (400 ± 20 psi) 
7  Torque converter inlet pressure tap  550 kPa (80 psi) 
8  Torque converter outlet pressure tap  415 ± 140 kPa (60 ± 20 psi) 
9  Transmission lubrication pressure tap  105 kPa (15 psi) 
10  Transmission pump pressure tap (If Equipped)  2758 ± 70 kPa (400 ± 10 psi) 
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(1) Oil pressure at high idle

Differential Pinion Preload - Adjust

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Table 19
Status(1)  Description  Specification  Actual  Comments 
Actual Torque at the pinion Torque Wrench Reading(2)
  New Bearings  1.2 ± 3.4 N·m (10.6 ± 30.1 lb in)  0.76 ± 2.15 N·m (6.73 ± 19.03 lb in)     
  Used Bearings  0.6 ± 1.7 N·m (5.3 ± 15.1 lb in)  0.38 ± 1.08 N·m (3.36 ± 9.56 lb in)     
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(1) N = Normal, M = Monitor, A = Action
(2) These readings are applicable when you are using a 203.0 mm (8.00 inch) torque wrench to rotate housing at the bolt circle.

Differential Backlash and Bearings - Adjust

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Table 20
Status(1)  Description  Specification  Actual  Comments 
Distance of dial indicator from the centerline of the pinion to the dial indicator Nominal Backlash  Maximum Backlash  Minimum Backlash 
  50.0 mm (1.97 inch)  0.28 mm (0.011 inch)  0.40 mm (0.016 inch)  0.18 mm (0.007 inch)     
  100.0 mm (4.00 inch)  0.57 mm (0.022 inch)  0.80 mm (0.032 inch)  0.35 mm (0.014 inch)     
  150.0 mm (5.91 inch)  0.86 mm (0.034 inch)  1.20 mm (0.047 inch)  0.53 mm (0.021 inch)     
  200.0 mm (7.87 inch)  1.15 mm (0.045 inch)  1.60 mm (0.063 inch)  0.70 mm (0.028 inch)     
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(1) N = Normal, M = Monitor, A = Action

Steering System

Reference: Refer to Testing & Adjusting, RENR8852, "Steering System" for more detail on the following test.

Piston Pump (Steering) High-Pressure Stall - Test and Adjust

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Table 21
Status(1)  Description  Specification  Actual  Comments 
  Piston Pump (Steering) High-Pressure Stall - Test  20700 ± 515 kPa (3002 ± 75 psi)     
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(1) N = Normal, M = Monitor, A = Action

Piston Pump (Steering) Margin Pressure - Test and Adjust

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Table 22
Status(1)  Description  Specification  Actual  Comments 
  Margin Pressure  2400 ± 150 kPa (348 ± 22 psi)     
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(1) N = Normal, M = Monitor, A = Action

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

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Table 23
Status(1)  Description  Specification  Actual  Comments 
  Piston Pump (Steering) Low-Pressure Standby - Test and Adjust  3600 kPa (522 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Pump Backup) - Test and Adjust

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Table 24
Status(1)  Description  Specification  Actual  Comments 
  Relief Valve (Pump Backup) - Test and Adjust  2100 ± 350 kPa (305 ± 51 psi)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Steering Cylinder Crossover) - Test and Adjust

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Table 25
Status(1)  Description  Specification  Actual  Comments 
  Steering Cylinder Crossover Relief Valve - Test and Adjust  25600 ± 500 kPa (3713 ± 73 psi)     
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(1) N = Normal, M = Monitor, A = Action

Steering Pilot System Pressure - Test (Command Control Steering)

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Table 26
Status(1)  Description  Specification  Actual  Comments 
  Steering Pilot System Pressure - Test (Command Control Steering)  Pressure should not below 1600 kPa (232 psi)     
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(1) N = Normal, M = Monitor, A = Action

Pilot Valve (Command Control Steering) Supply Pressure - Test and Adjust

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Table 27
Status(1)  Description  Specification  Actual  Comments 
  Neutral pilot pressure  600 ± 35 kPa (87 ± 5 psi)     
  Supply pressure for the pilot valve  3500 ± 250 kPa (508 ± 36 psi)     
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(1) N = Normal, M = Monitor, A = Action

Brake and Hydraulic Fan System

Reference: Refer to Testing & Adjusting, RENR8855 for more detail on the following test.

Brake Accumulator - Test and Charge

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Table 28
Status(1)  Description  Specification  Actual  Comments 
  Brake Accumulator - Test and Charge  6200 kPa (899 psi)     
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(1) N = Normal, M = Monitor, A = Action

Service Brake System Pressure - Test

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Table 29
Status(1)  Description  Specification  Actual  Comments 
  Service Brake System Pressure - Test  4690 ± 350 kPa (680 ± 51 psi)     
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(1) N = Normal, M = Monitor, A = Action

Control Manifold (Charging Valve for the Brake Accumulators) - Test and Adjust

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Table 30
Status(1)  Description  Specification  Actual  Comments 
  Cut-out pressure  15000 ± 350 kPa (2176 ± 51 psi)     
  Cut-in pressure  12800 ± 345 kPa (1857 ± 50 psi)     
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(1) N = Normal, M = Monitor, A = Action

Service Brake Wear Indicator (Existing Brake Disc) - Check

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Table 31
Status(1)  Description  Specification  Actual  Comments 
Estimated Percentage of Remaining Brake Disc Life Amount of the Friction Material that is Worn forms the Discs Oil Groove Depth(2) 
  Disc Thickness wear chart for standard service brakes  100  0.00 mm (0.000 inch)  1.05 mm (0.041 inch)     
  80 0.58 mm (0.023 inch)  0.90 mm (0.035 inch)     
  60 1.16 mm (0.046 inch)  0.76 mm (0.030 inch)     
  40 1.76 mm (0.069 inch)  0.61 mm (0.024 inch)     
  20 2.34 mm (0.092 inch)  0.47 mm (0.019 inch)     
  0 2.92 mm (0.115 inch)  0.32 mm (0.013 inch)     
  Disc Thickness wear chart for logging attachment service brakes  100  0.00 mm (0.000 inch)  0.90 mm (0.035 inch)     
  80 0.66 mm (0.026 inch)  0.79 mm (0.031 inch)     
  60 1.32 mm (0.052 inch)  0.68 mm (0.027 inch)     
  40 1.98 mm (0.078 inch)  0.57 mm (0.022 inch)     
  20 2.64 mm (0.104 inch)  0.46 mm (0.018 inch)     
  0 3.30 mm (0.130 inch)  0.35 mm (0.014 inch)     
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(1) N = Normal, M = Monitor, A = Action
(2) Groove depth is the most critical measurement

Air Pump (Variable Pitch Fan) Pressure - Test

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Table 32
Status(1)  Description  Specification  Actual  Comments 
  Air Pump (Variable Pitch Fan) Pressure - Test  760 kPa (110 psi)     
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(1) N = Normal, M = Monitor, A = Action

S.O.S

Reference: Refer to Operation and Maintenance Manual, SEBU7887, "Maintenance Interval Schedule" for more detail on the following test.

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Table 33
Status(1)  Description  Obtain  Comments 
  Engine Coolant Sample (Level 1)     
  Engine Coolant Sample (Level 2)     
  Engine Oil Sample     
  Hydraulic Oil Sample     
  Transmission/Differential Oil Sample     
  Tandem Drive Oil Sample     
  Wheel Bearing Oil Sample (Front)     
Show/hide table
(1) N = Normal, M = Monitor, A = Action

Caterpillar Information System:

Port 1 Settings May Revert Back From Master Status to Slave Status on Certain Cat® Product Link Devices Installed on Track-Type Tractors {7338, 7600, 7606} Port 1 Settings May Revert Back From Master Status to Slave Status on Certain Cat® Product Link Devices Installed on Track-Type Tractors {7338, 7600, 7606}
A New Special Instruction for Installation Procedure to Retrofit a PL321VSR Electronic Control Module (ECM) With a Pro Product Link PL641 or PL631 or PL542 Systems is Now Available {7606} A New Special Instruction for Installation Procedure to Retrofit a PL321VSR Electronic Control Module (ECM) With a Pro Product Link PL641 or PL631 or PL542 Systems is Now Available {7606}
Installation Procedure to Retrofit a PL321VSR Electronic Control Module (ECM) With a Pro Product Link PL641 or PL631 or PL542 Systems {7606} Installation Procedure to Retrofit a PL321VSR Electronic Control Module (ECM) With a Pro Product Link PL641 or PL631 or PL542 Systems {7606}
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An Improved Coolant Hose is Now Used on Certain D9T Track-Type Tractors {1380} An Improved Coolant Hose is Now Used on Certain D9T Track-Type Tractors {1380}
Installing New Threaded Inserts on Certain D-Series Wheel Skidder Cabs {0679, 7301} Installing New Threaded Inserts on Certain D-Series Wheel Skidder Cabs {0679, 7301}
AD22 Underground Articulated Truck Power Train Electronic Control System Electronic Control Module (ECM) - Replace - Software Update Procedure
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Additional Emergency Stop Near Fast fill Service Center is Now Available on Certain MD6250 and MD6310 Rotary Drills {1408, 7415} Additional Emergency Stop Near Fast fill Service Center is Now Available on Certain MD6250 and MD6310 Rotary Drills {1408, 7415}
D6 XE Track-Type Tractor Power Train Power Inverter - Assemble
D6 XE Track-Type Tractor Power Train Power Inverter - Disassemble
An Improved Manufacturing Process Is Now Used for the Transmission Control Group On Certain Compact Wheel Loaders {3065, 3168, 7451} An Improved Manufacturing Process Is Now Used for the Transmission Control Group On Certain Compact Wheel Loaders {3065, 3168, 7451}
3512E Oil Well Service Engine Safety Messages
A New Line Pressure Relief Valve is Now Used on the Rod End of the Boom Cylinder Control Valve On Certain D Series Wheel Skidders {5051, 5264} A New Line Pressure Relief Valve is Now Used on the Rod End of the Boom Cylinder Control Valve On Certain D Series Wheel Skidders {5051, 5264}
986K Large Wheel Loader Systems General Information (Fan Hydraulic System)
3512E Oil Well Service Engine Model View Illustrations
D11R Track-Type Tractor High Pressure Screens - Clean/Replace - If Equipped
D11 Track-Type Tractor Fuel Tank Cap Filter and Strainer - Replace/Clean
903 D Wheel Loader Power Train Transfer Drive and Trunnion (Hydrostatic) - Remove and Install
903 D Wheel Loader Power Train Transfer Drive and Trunnion (Hydrostatic) - Disassemble
Procedure To Tighten Lower Retention Bolts On Certain M Series Medium Wheel Loaders {7057, 7100} Procedure To Tighten Lower Retention Bolts On Certain M Series Medium Wheel Loaders {7057, 7100}
903 D Wheel Loader Power Train Transfer Drive and Trunnion (Hydrostatic) - Assemble
Bearings On Differential Bevel Gear Group May Experience Pitting or Spalling On Certain 966L, 966M, 972L, 972M, and 972M XE Medium Wheel Loaders {3254, 3256} Bearings On Differential Bevel Gear Group May Experience Pitting or Spalling On Certain 966L, 966M, 972L, 972M, and 972M XE Medium Wheel Loaders {3254, 3256}
Differential Bevel Gear Set Can Fail On Certain 966M, 966M XE, 972M, and 972M XE Medium Wheel Loaders {3254, 3256} Differential Bevel Gear Set Can Fail On Certain 966M, 966M XE, 972M, and 972M XE Medium Wheel Loaders {3254, 3256}
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