TA-2 Visual & Technical Inspection for Wheel Loaders

TA-2 Visual & Technical Inspection for Wheel Loaders
SMCS - Job Code - 540 Component Code - 753T
Cat dealer Customer

Address Address
Contact Contact
Serial Number : A6G Inspector : Temperature :

Model : 966H Work Order : Time :
Engine S/N: SMU: Date :
Manufacturer : Unit Location:
Note: Review Machine & S·O·S History and check for Active Service Letters prior to inspection.
Status of the Machine

Normal
The status recommendation of your Wheel Loader is:
737373Caterpillar: Confidential Green

#
Visual Inspection for Wheel Loaders
Status assessment ü– Normal M – Monitor A – Action Blank – Not Applicable
1. Prepare Machine Inspection

# Status Description Comments
1.1 Check with customer for operator complaints
1.2 Prepare the machine for the inspection
1.3 Perform safety/preparatory inspection
1.4 Download machine fault codes

1.5 https://productsupportglobalcontent.cat.com/cda/files/712700/7/Product%20Link%20Dealer%20Validation.pdf
1.5 Check Product Link
Is machine equipped with PL?
Is PL activated?
Is PL functioning properly?
1.6 Observe engine exhaust colors
1.7 Listen for unusual noises

(hydraulic pumps, engine, transmission, and axles)
1.8
1.9
1.10
Item No. Additional Comments
# 737373Caterpillar: Confidential Green

2. Lower Level Inspection
2.1 Tires and rims
2.2 Final drives and wheel spindles
2.3 Front and rear differentials
2.4 Front, center, and rear drive shafts
2.5 Center support bearing

Torque converter, transmission and transfer gear box
2.6
compartment
2.7 Hydraulic pump compartment
2.8 Upper and lower hitch pins/bores
2.9 Main machine frame
2.10
2.11
2.12
2.13

3. Middle Level Inspection
3.1 Steps and handrails
3.2 Work light/hazard lights
3.3 Cab mounts

Steering control valve, steering neutralizer valve, brake
3.4
valve, and HMU
3.5 Implement control valve
3.6 Radiator, oil cooler, condenser, and aftercooler
3.7 Oil cooler and condenser lines
3.8 Hood and platform
3.9 Battery and battery cables
3.10 Fenders
3.11 Lower radiator and oil cooler hoses
3.12 Engine oil pan
3.13
3.14
3.15

4. Upper-Level Inspection
4.1 Cab exterior
4.2 Cab interior
4.3 Pre-cleaner and air cleaner
4.4 Upper radiator, air inlet, oil cooler, and aftercooler lines
4.5 Radiator cap
4.6 Water pump
4.7 Fuel lines and fuel pump
4.8 Exhaust manifold
4.9 Turbocharger
4.10 Cylinder head and valve cover
4.11 Belts, pulleys, compressor clutch, and fan motor
4.12 Cooling fan, fan guard, and shroud
4.13 Engine wiring harness
4.14 Engine mounts
4.15
4.16
4.17

5. Implement/Attachment Inspection
5.1 Lift cylinder
5.2 Area where lift arm attaches to frame
5.3 Tilt cylinder
5.4 Area where tilt lever attaches to lift arm
5.5 Bucket linkage
5.6 Bucket wear plates
5.7 Bucket side cutters
5.8 Bucket edges, tips, and adapters
5.9
5.10
5.11
Other Remarks

Technical Inspection for Wheel Loaders
Status assessment ü- Normal M - Monitor A - Action Blank – Not Applicable
NOTE: Prior to making any system adjustments, please consult the Service Information System (SIS) for the latest specifications.
1. Engine
1.1Cooling System
Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.1.1 Radiator Pressure Relief (Radiator Cap) KPA - - - Test for pressure listed on radiator cap
1.1.2 1.1.2 Test Engine Coolant
Check Freezing Point of Engine Coolant Use 245-5829 Coolant/Battery Tester/Refractometer.
Test Engine Coolant Conditioner Use 8T-5296 Conditioner Test Kit.
1.1.3 Check Belt Tension Auto Tension
1.1.4 Engine Coolant Temperature C 89 3 3 From test specification 0K4835.
1.1.5 Radiator Temperature Drop (Out - In) C 2 5 5 From test specification 0K4835.
1.2 Fuel System

*Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.2.1 1.2.1 Engine Speed - Check
No Load High Idle RPM 2270 40 40 From test specification 0K4835.
No Load Low Idle RPM 825 10 10 From test specification 0K4835.
1.2.2 1. Fuel System Pressure - Test
Fuel Pressure at Low Idle KPA

From test specification 0K4835.
Fuel Pressure at High Idle KPA 630 184 224
1.3 Lubrication System

# *Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.3.1 1.3.1 Engine Oil Pressure - Test
Oil Pressure at Low Idle KPA 185 415 125 From test specification 0K4835.
Oil Pressure at High Idle KPA 360 240 180 From test specification 0K4835.
1.4 Basic Engine

1.4.1 Cylinder Cutout Test - - - Use Cat ET to perform test
1.4.2 Engine Crankcase Pressure (Blowby) Test - - - See Tables tab for Blowby Tools.

#
1.5 Air Inlet and Exhaust System
Status Description Units Observed Minimum Maximum Comments
1.5.1 1.5.1 Torque Converter Stall Test (from T&A Power Train System)
Torque Converter Oil Temperature C 75 105
105 Units Observed Specified (+)Tol (-)Tol

Boost Pressure (Adjusted Boost Pressure from TMI) KPA 124 19.8 17.8 Adj Boost at TC RPM from test specification 0K4835.
Fully depress the right side service brake pedal. Shift the transmission
direction control and speed control to the FOURTH SPEED FORWARD
Engine Speed (from T&A Power Train System) RPM 2185 65 65 position. Hold the brake pedal in the depressed position for the duration of
the test.
1.5.2 Exhaust Temperature - Test (Measure at Each Cylinder) Units Cyl Observed Cyl Observed
#1 Even #2 Even
Even #3 Even #4 Even

1.6 Miscellaneous Engine
1.6.1
1.6.2
1.6.3
2. Performance Checks
2.1 Hydraulc Performance Checks
2.1.1 2.1.1 Implement Cycle Time - Check
Lift Raise Sec 6.5 1.5 0.5
Lift Lower Sec 3.5 0.5 0.5
Float Sec 2.8 0.5 0.5
Tilt Back Sec 2.5 0.5 0.5
Dump Sec 2.7 0.5 0.5
2.1.2 2.1.2 Lift & Tilt Cylinder Drift - Check

Oil Temperature Units Observed Oil Temperature Ranges
C ??° to ??° ??° to ??° ??° to ??°
38 to 49 50 to 65 66 or more
Units Observed Maximum Allowable Minimun Allowable Minimun Allowable Minimun Allowable
Movement Time (sec) Time (sec) Time (sec)
Lift Cylinder 300 162 102

Sec 14mm
Tilt Cylinder 162 102
Sec 20mm
2.2 Brake Performance Checks
2.2.1 Brake Accumulator - Test (Test from OMM) - - - See Brake Accumulator Test in Tables tab.
2.2.2 Service Brake Holding Ability Test (Test from OMM) - - - See Service Brake Holding Test in Tables tab.
2.2.3 Parking Brake Holding Ability Test (Test from OMM) - - - See Parking Brake Holdig Test in Tables tab.
#
2.3 Steering Performance Checks
2.3.1 2.3.1 Command Control Steering Steering Time - Check
Left Steering Time (High Idle)

Sec 2.9 0.5 0.5
Right Steering Time (High Idle)

Sec 2.9 0.5 0.5
Left Steering Time (Low Idle) - - -
Right Steering Time (Low Idle) - - -
Left/Right Time Difference (Max) Sec 0.3

2.3.2
2.3.2 HMU Steering Time - Check
Left Steering Time (High Idle) Sec 2.9 0.5 0.5

Right Steering Time (High Idle) Sec 2.9 0.5 0.5
Left Steering Time (Low Idle) Sec 4.9 0.5 0.5
Right Steering Time (Low Idle) Sec 4.9 0.5 0.5
Left/Right Time Difference (Max) Sec 0.3
3. Hydraulics
3.1 Hydraulic System
Status Description Units Observed Minimum Maximum Comments
C Units Observed Specified (+)Tol (-)Tol Comments
Boost Pressure (Adjusted Boost Pressure from TMI) NA
Engine Speed (from T&A Hydraulic System) NA
3.1.1 Implement Piston Pump Margin Pressure (Float) KPA 2100 100 100
3.1.2 Pilot Pressure to the Main Control Valve - Check KPA 3515 345 345
3.1.3 Load Sensing Signal Relief Valve - Test and Adjust KPA 31000 690 690
3.1.4 3.1.4 Pilot Oil Accumulator (Dead Engine Lower) - Test Units Observed Oil Temperature Ranges
Oil Temperature Ranges Oil Temperature ??° to ??° ??° to ??° ??° to ??°
??° to ??°
??° to ??° Units Observed Specified (+)Tol (-)Tol Comments
Accumulator Pressure (High Idle) KPA 3515 345 345
Accumulator Pressure (Dead Engine Lower) KPA 2000 100 100

3.1.5 3.1.5 Ride Control Accumulator - Test Units Observed Oil Temperature Ranges
Oil Temperature ??° to ??° ??° to ??° ??° to ??°
Units Observed Specified (+)Tol (-)Tol Comments

See Accumulator Precharge Pressure/Temperature Relationship chart in
Charge Pressure (at Ambient Temperature)
Tables tab.

#
3.2 Miscellaneous Hydraulic System
3.2.1
3.2.2
3.2.3
4. Brake and Hydraulic Fan

4.1 Braking System
4.1.1 4.1.1 Service Brake System Pressure - Test
Rear Service Brake Pressure (Brake On) KPA 4690 390 390
Front Service Brake Pressure (Brake On) KPA 4690 390 390
4.1.2 4.1.2 Service Brake Wear Indicator

Right Front See Disc Thickness Wear Chart in Tables tab. 2.92 mm measurement or
Indicator Depth MM greater replace discs.
Left Front See Disc Thickness Wear Chart in Tables tab. 2.92 mm measurement or
Right Rear See Disc Thickness Wear Chart in Tables tab. 2.92 mm measurement or
Left Rear See Disc Thickness Wear Chart in Tables tab. 2.92 mm measurement or
4.2 Hydraulic Fan System
4.2.1 4.2.1 Hydraulic Fan (If Equipped)
Max Fan Speed 1200 50 50 Variable pitch fan, set the fan speed to 1350 ± 50 rpm.
Min Fan Speed 500 50 50 Variable pitch fan, set the fan speed to 525 ± 75 rpm.
Margin Pressure (Low Idle) 1800 100 100
High Pressure Cut-Off (High Idle) 18800

4.3 Miscellaneous Brake and Hydraulic Fan System
4.3.1
4.3.2
4.3.3
5. Steering
5.1 Steering System
5.1.1 Piston Pump (Steering) High Pressure Stall - Test KPA 20700 515 515
5.1.2 5.1.2 Piston Pump (Steering) Margin Pressure - Test
Steering Pump Pressure KPA 20700 515 515
Steering Metering Pump Signal Pressure

Margin pressure is the difference between steering pump pressure and the
Margin Pressure 2400 150 150
KPA signal pressure from steering metering pump.
5.1.3 Piston Pump (Steering) Low Pressure Standby - Test 3600 Maximum
KPA
When the pump stall pressure is reached, continue to turn adjustment
5.1.4 HMU Relief Valve (Pump Backup) - Test 20865 515 515
KPA screw (5) clockwise by one full turn.

#
5.1.5 HMU Steering Cylinder Crossover Relief Valve - Test KPA 25600 500 500

#
5.1.6 5.1.6 Command Control Steering Pilot System Pressure - Test
Left Steering Pilot Pressure (Min) 1600 Minimum Pressure

KPA
Right Steering Pilot Pressure (Min) 1600 Minimum Pressure
KPA
5.1.7 Command Control Steering Pilot Valve Supply Pressure - Test KPA 3500 250 250
5.1.8 5.1.8 Steering Neutralizer Valve - Check KPA 600 35 35
Right Side Gap (Engine Frame to Non-Engine Frame) MM 12.7 3.0 3.0
Left Side Gap (Engine Frame to Non-Engine Frame) MM 12.7 3.0 3.0
5.2 Miscellaneous Steering
5.2.1
5.2.2
5.2.3
6. Power Train
6.1 Power Train System
6.1.1 6.1.1 Tire Pressure
Front Left Tire Pressure See Tire Manufacture recommendations
Front Right Tire Pressure See Tire Manufacture recommendations
Rear Left Tire Pressure See Tire Manufacture recommendations
Rear Right Tire Pressure See Tire Manufacture recommendations
Status Description Pass Fail Comments

6.1.2 Calibrate Fill Time for the Transmission Clutch
6.1.3 6.1.3 Test for the Transmission Clutch Pressure
Clutch 1 Pressure (Reverse in Any Speed) KPA 2758 140 140
Clutch 2 Pressure (Forward in Any Speed) KPA 2758 140 140
Clutch 3 Pressure (Nuetral) KPA 2758 140 140
Clutch 4 Pressure (Forward or Reverse/Third Speed) KPA 2758 140 140
Clutch 5 Pressure (Second Speed/Forward or Reverse) KPA 2310 140 140
Clutch 6 Pressure (First Speed/Forward or Reverse) KPA 2758 140 140
6.1.4 Torque Converter Inlet Pressure (High Idle) KPA 550
6.1.5 Torque Converter Outlet Pressure (Torque Converter Stall) KPA 415 140 140
6.1.6 Transmission Lubrication Pressure (High Idle) KPA 105
6.1.7 Transmission Oil Pump Pressure (High Idle) KPA 2758 70 70

#
6.2 Miscellaneous Power Train
6.2.1
6.2.2
6.2.3
7. Electrical System
7.1 Electrical System
7.1.1 7.1.1 Battery Voltage
Engine Stopped - - - Use 4C4911 Battery Load Tester .
Low Idle - - -
High Idle V 28 1 1
7.1.2 Inspect Battery Cables
7.1.3 Starter Draw Test 76.5 14.5 14.5 No load conditions at 25 °C.
A
7.2 Miscellaneous Electrical
7.2.1
7.2.2
7.2.3
8. S·O·S
8.1 S·O·S Samples
Status Description Obtain Comments
8.1.1 Engine Oil Sample
8.1.2 Engine Coolant Sample (Level II)
8.1.3 Hydraulic Oil Sample
8.1.4 8.1.4 Differential & Final Drive Oil Samples (Inboard Final Drives)
Front Differential & Final Drive Oil Sample
Rear Differential & Final Drive Oil Sample
8.1.5 8.1.5 Differential & Final Drive Oil Samples (Outboard Final Drives)
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
8.1.6 Transmission/Torque Converter Oil Sample

#
Blowby Tools Needed
Brake Accumulator - Check
Part Part Quantity

Number Name

285-0910 Multi-Tool 1 SMCS - 4263-535
Gp
285-0900 Blowby 1
Tool
Group
NETG504 Software 1
4 license
1. Turn the engine start switch to the ON position. The alert indicator
at normal operating pressure.
2. Start the engine. Run the engine at half speed for two minutes in o
brake oil pressure should go off.
3. Stop the engine. Apply the service brake pedal and release the s
comes on. This will decrease the accumulator pressure. A minimum o
4. If the alert indicator comes on after less than five applications

authorized Caterpillar dealer can measure the nitrogen gas pressure

Service Brake Hold
sition. The alert indicator for brake oil pressure should come on if the braking system is not 1. Start the engine. Raise the imple
speed for two minutes in order to increase the accumulator pressure. The alert indicator for 2. Move the transmission control t
control is in the OFF position.
e pedal and release the service brake pedal until the alert indicator for brake oil pressure 3. Gradually increase the engine sp
or pressure. A minimum of five applications of the service brake pedal are required.
s than five applications of the brake, measure the accumulator precharge pressure. An 4. Reduce the engine speed to low
he nitrogen gas pressure in the accumulator. Use only dry nitrogen gas for recharging. Lower the implement to the ground
If the machine moved during the t

machine is returned to operation.

ce Brake Holding Ability Test
e engine. Raise the implement slightly. Apply the service brake. Release the parking brake.
he transmission control to THIRD SPEED FORWARD while the service brakes are applied. Make sure that the autoshift
in the OFF position.
ally increase the engine speed to high idle. The machine should not move.
e the engine speed to low idle. Move the transmission direction control to the NEUTRAL position. Engage the parking brake.
implement to the ground. Stop the engine.
chine moved during the test, consult your Caterpillar dealer for a brake inspection. Make any necessary repairs before the
s returned to operation.

Parking Brake Holding Ability Test
This test is performed when the parking brake is engaged. If the machine begins to move, compare the engine rp
of a prior test. This will indicate the amount of system deterioration.
1. Start the engine. Raise the implement slightly. Engage the parking brake.
2. Move the transmission control to THIRD SPEED FORWARD. Make sure that the autoshift control is in the OF
The parking brake indicator light should come on.
3. Gradually increase the engine speed to high idle. The machine should not move.
4. Reduce the engine speed to low idle. Move the transmission direction control to the NEUTRAL position. Lower
ground. Stop the engine.

4. Reduce the engine speed to low idle. Move the transmission direction control to the NEUTRAL position. Lowe
If the machine moved during the test, consult your Caterpillar dealer for a brake inspection. Make any necessary re

966H Accumulator Precharge
Pressure/Temperature Relationship for a
Typical Ride Control Accumulator with a
Precharge of
2960 kPa (430 psi)
Temperature Pressure (1)
-7°C (20°F) 2690 kPa (390 psi)
-1°C (30°F) 2745 kPa (398 psi)
e, compare the engine rpm to the engine rpm 4°C (40°F) 2800 kPa (406 psi)
10°C (50°F) 2855 kPa (414 psi)

16°C (60°F) 2910 kPa (422 psi)
21°C (70°F) 2960 kPa (430 psi)

oshift control is in the OFF position. 27°C (80°F) 3020 kPa (438 psi)
32°C (90°F) 3075 kPa (446 psi)

38°C (100°F) 3130 kPa (454 psi)
43°C (110°F) 3185 kPa (462 psi)

49°C (120°F) 3240 kPa (470 psi)
( 1 )
Nominal allowable tolerance
equals ± 35 kPa (± 5 psi).
EUTRAL position. Lower the implement to the

NEUTRAL position. Lower the implement to the ground. Stop the engine.
n. Make any necessary repairs before the machine is returned to operation.

Disc Thickness Wear Chart for Standard Service Brakes
Estimated Percentage Amount of the Friction Oil Groove Depth (1)

of Remaining Brake Material that is Worn
Disc Life From the Discs
100 0.00 mm (.000 inch) 1.05 mm (.041 inch)
80 0.58 mm (.022 inch) 0.90 mm (.036 inch)
60 1.16 mm (.046 inch) 0.76 mm (.030 inch)
40 1.76 mm (.068 inch) 0.61 mm (.024 inch)
20 2.34 mm (.092 inch) 0.47 mm (.018 inch)

0 2.92 mm (.116 inch) 0.32 mm (.013 inch)
( 1 )
Groove depth is the most critical
measurement.

TA-2 Visual & Technical Inspection for Wheel Loaders

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TA-2 Visual & Technical Inspection for Wheel Loaders

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TA-2 Visual & Technical Inspection for Wheel Loaders

SMCS - Job Code - 540 Component Code - 753T

Cat dealer Customer

Serial Number : A6G Inspector : Temperature :

Status of the Machine

737373Caterpillar: Confidential Green

1. Prepare Machine Inspection

1.1 Check with customer for operator complaints

1.2 Prepare the machine for the inspection

1.3 Perform safety/preparatory inspection

1.4 Download machine fault codes

Is machine equipped with PL?

1.6 Observe engine exhaust colors

1.7 Listen for unusual noises

# 737373Caterpillar: Confidential Green

2.1 Tires and rims

2.2 Final drives and wheel spindles

2.3 Front and rear differentials

2.4 Front, center, and rear drive shafts

2.5 Center support bearing

2.8 Upper and lower hitch pins/bores

2.9 Main machine frame

# 737373Caterpillar: Confidential Green

3.1 Steps and handrails

3.2 Work light/hazard lights

3.3 Cab mounts

3.6 Radiator, oil cooler, condenser, and aftercooler

3.7 Oil cooler and condenser lines

3.8 Hood and platform

3.9 Battery and battery cables

3.11 Lower radiator and oil cooler hoses

3.12 Engine oil pan

# 737373Caterpillar: Confidential Green

4.1 Cab exterior

4.2 Cab interior

4.3 Pre-cleaner and air cleaner

4.5 Radiator cap

4.6 Water pump

4.7 Fuel lines and fuel pump

4.8 Exhaust manifold

4.10 Cylinder head and valve cover

4.11 Belts, pulleys, compressor clutch, and fan motor

4.12 Cooling fan, fan guard, and shroud

4.13 Engine wiring harness

4.14 Engine mounts

# 737373Caterpillar: Confidential Green

5.1 Lift cylinder

5.2 Area where lift arm attaches to frame

5.3 Tilt cylinder

5.4 Area where tilt lever attaches to lift arm

5.5 Bucket linkage

5.6 Bucket wear plates

5.7 Bucket side cutters

5.8 Bucket edges, tips, and adapters

# 737373Caterpillar: Confidential Green

1.1.2 1.1.2 Test Engine Coolant

Check Freezing Point of Engine Coolant Use 245-5829 Coolant/Battery Tester/Refractometer.

Test Engine Coolant Conditioner Use 8T-5296 Conditioner Test Kit.

1.1.3 Check Belt Tension Auto Tension

1.1.4 Engine Coolant Temperature C 89 3 3 From test specification 0K4835.

1.2 Fuel System

No Load High Idle RPM 2270 40 40 From test specification 0K4835.

No Load Low Idle RPM 825 10 10 From test specification 0K4835.