Technical Analysis 1 (TA1) Visual Inspection for Knuckle Boom Loader {0372, 0374, 1000, 7000, 753S, 7565} Caterpillar

Knuckleboom Loader

2384C (S/N: KB61-UP; KAW1-UP)

2484C (S/N: KB71-UP; KAZ1-UP)

539 (S/N: 1PZ1-UP)

559C (S/N: KB41-UP; KAS1-UP)

579C (S/N: KB51-UP; KAX1-UP)

C6.6 (S/N: 5591-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 before problems occur.

Note: Before adjusting product settings to comply with listed baseline TA1 values, consult SIS for the latest specification values.

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Visual Inspection

1.0 Prepare Machine Inspection

Refer to "1.0 Inspection Preparation"section in "Inspection Reference" for more information for performing machine inspection preparation.

2.0 Ground Level Inspection

Refer to "2.0 Ground Level Inspections" section in "Inspection Reference" for more information for performing ground level inspection.

3.0 Middle-Level Inspection

Refer to "3.0 Middle-Level Inspections:" section in "Inspection Reference" for more information for performing middle-level inspection.

4.0 Upper-Level Inspection

Refer to "4.0 Upper-Level Inspections:" section in "Inspection Reference" for more information for performing upper-level inspection.

5.0 Implement/Attachment Inspection

Refer to "5.0 Implement/Attachment Inspections:" section in "Inspection Reference" for more information for performing implement/attachment inspection.

6.0 Site Conditions

Inspection Reference

Inspection Benefits:

• Minimizes downtime through scheduled maintenance

• Locates potential problems

• Identifies overlooked problems

• Enables scheduled maintenance and repairs

• Lowers owning and operating costs

1.0 Inspection Preparation

1.1 Check with customer for operator complaints

1.2 Prepare the machine for the inspection

• Verify that the area is free of personnel: check underneath the machine, around the machine, and on the machine.

• Open or remove any covers needed to gain access to components.

1.3 Perform safety inspections

• Verify that all safety equipment is in place

1.4 Listen for unusual noises

• Engine/hydraulic pump

1.5 Check LEDs on electrical enclosure or PLC display

• Verify that there are no trouble lights active

1.6 Check all required approval plates are attached

• Tags are normally located near electrical enclosure. See tag placement drawing in parts book to identify location.

1.7 Check for fluid leaks

• Check for hydraulic fluid leaks

2.0 Ground Level Inspections

Inspect:

2.1 Tires and Rims

• Check tires for proper inflation, tire cuts, cracks, and general condition

• Check rims for cracks or other structural damage

2.2 Wheel Spindles (if equipped)

• Check for excessive grease

• Check for rust or other damage

2.3 Front Stabilizers

• Check for external leaks. If there is oil coming out, dirt is going in.

• Check for nicks, gouges, or deep scratches.

2.4 Rear Stabilizers

• Check for external leaks. If there is oil coming out, dirt is going in.

• Check for nicks, gouges, or deep scratches.

2.5 Main Frame

• Check for cracks and other damage especially in high stress areas where frames intersect other components or have sharp edges.

• Check for signs that frame is out of square such as uneven components or stress marks.

2.6 Main Frame Hitch

• Check for damage, cracks, or other impact damage

2.7 Implement Extension Frame

• Check for cracks and other damage especially in high stress areas where frames intersect other components of have sharp edges.

2.8 Swing area mounted to Frame

• Check for cracks and other damage especially in high stress areas.

3.0 Middle-Level Inspections:

Inspect:

3.1 Cab exterior

• Bent or damaged cab structure

• Cracked or broken glass

• Damaged or missing mirrors

• Worn or broken window wiper arm or wiper blade

3.2 Steps and handrails

Ensure that steps and handrails are in place and check for:

• Damaged, missing, or loose bolts

• Damage to steps or handrails

• Excessive dirt or debris

3.3 Work lights (if equipped)

• Proper operation

• Cracked or broken lenses

• Damaged harnesses or electrical connectors

• Loose or damaged mounting brackets

3.4 Air cleaner and air filter service indicator

• Dirt and/or debris in the air pre-cleaner

• Loose or damaged hose clamps on air inlet tube

3.5 Batteries and cables

• Corrosion on battery posts and/or cables

• Proper function and tightness of battery hold down

3.6 Condenser and aftercooler

• Plugged cores

• Plugged screens

• Damaged fins

3.8 Lower radiator hoses

• Rubbing, cracked, or damaged hoses

• Loose or damaged hose clamps

3.9 Aftercooler/condenser fan guard and fan

• Rubbing, cracked, or damaged

• Loose or damaged fasteners

3.10 Pulleys, belts, and compressor clutch

• Worn, cracked, or broken belts

• Proper belt tension

• Oil leaks around air conditioning compressor clutch

3.11 Alternator, pulley, belts, and mounting

• Loose, worn, cracked, or broken belts

• Worn or bottomed out pulleys

• Broken or damaged mounting brackets

3.12 Water Pump

• Coolant leaks around water pump mounting flange

• Coolant leaks through the weep hole in the water pump housing

3.13 Turbocharger

• Oil leakage around the turbocharger oil line

• Loose or damaged hose clamp on air inlet tube

• Black soot around the areas where the turbocharger bolts to the exhaust manifold or to the pipe, which would indicate:

- Loose connection at the joint

- Loose or broken mounting bolts

3.14 Exhaust Manifold

• Cracks or other damage in the manifold housing

• Black soot around the sealing surface where the exhaust manifold bolts to the engine block, which may indicate:

- Loose connection at the joint

- Loose or broken manifold bolts

3.15 Engine oil filter bases and filters

• External leaks

• Cracks or leaking plugs

3.16 Fuel filter bases, fuel filters, and water separator

• Damaged, rubbing, or worn fuel lines

• Loose connections

3.17 Fuel priming pump and fuel lines

• Damaged, rubbing, or worn fuel lines

• Loose connections

3.18 Engine oil pan

• Loose bolts, leaks, or impact damage

• Packed material or cracking

3.19 Engine wiring harness

• Rubbing, cracked, damaged, or exposed harnesses

• Loose or damaged hose clamps

3.20 Engine Mounts

• Loose or damaged bolts

• Wear or damage to rubber mounts

3.21 Exhaust tube and muffler

• Black soot around the sealing surface and other signs of extreme heat

• Loose connection at the joint

3.22 Hydraulic pump compartment

• Leaks around hose connection points

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

• Loose or damaged hose clamps on main pump suction lines

4.0 Upper-Level Inspections:

Inspect:

4.1 Cab Interior

• Excessive dirt in cab air filter

• Proper function of the seat and seat belt

• Wear or damage to seat belt

• Proper function of door and latches

• Worn or broken window latches or slides

4.2 Indicators and gauges

• Check for proper operation

• Check for physical damage

4.3 Seat and seat belts

• Seat belt replacement date

• Check seat condition for support and comfort

• Check for a copy of the OMM

4.4 Hood and platform

• Proper function of hood and latches

• Debris or excessive dirt on service platform

4.5 Fuel tank, cap, and strainer

Check for:

• Leaks

• Structural damage to tank, welds

• Breather and fill cap

• Loose or damaged bolts

• Worn or damaged rubber mounts

4.6 Hydraulic tank

Check:

• Upper and lower mounts for loose mounting bolts and structural cracks on frame mounting brackets

• Tank cap seals for damage

• Breather for dirt and debris buildup

• Hydraulic lines for leaks, loose or damaged connections

• Sight glass covers for damage

• Sight glasses for damage or leaks

4.7 Radiator/oil cooler fan guard and fan

• Loose, damaged, or missing bolts

• Damaged wire fan guard

• Cracked or missing blades on the engine fan

4.8 Radiator and oil cooler

• Rubbing, cracked, or damaged hoses

• Loose or damaged hose clamps

4.9 Radiator and oil cooler lines

• Rubbing, cracked, or damaged hoses

• Loose or damaged hose clamps

4.10 Main hydraulic control valve

• Leaks around hose connection points

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

4.11 Hydraulic lines and couplings

• Leaks around hose connections

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wires/harness/connectors

4.12 Swing drive compartment

• Leaks around hose connection points

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

4.13 Swing drive motor

• Leaks around hose connection points

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

4.14 Swing drive

Check the swing drive oil level; if the oil level is low, check the following areas for leaks:

• Sealing surface between the cover and the ring gear

• Sealing surface between the ring gear and the housing

• Joint where the dipstick tube connects to the swing drive housing

• If no leakage is found in these areas, leakage may be caused from a worn pinion shaft or bottom cover seal. To service these seals, the swing drive must be removed

4.15 Fuel pump and fuel lines

• Check for leaks, rubbing, and proper clamps

4.16 Cylinder head and valve cover

• Fuel leaks around and below the protective guard located above the fuel lines. If fuel leaks are present on the intake manifold, remove the guard and inspect fuel lines for leaks.

• Oil and dust buildup around the valve cover sealing surface, which could indicate:

- Loose connection at the joint

- Damaged gasket or seal

4.17 Radiator cap

• Gaskets for wear or damage

4.18 ROPS

• Inspect for cracks or impact damage

• Inspect for unauthorized modifications (welds, brackets…)

5.0 Implement/Attachment Inspections:

Inspect:

5.1 Inspect area around boom cylinders and swivel for:

• Leaks around hose connection points

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

• Boom cylinder linkage pin wear (refer to “Pin Inspection Guidelines” for inspection procedure)

5.2 Boom, boom pins, and bearings

• Check for excessive movement in pins and bushings

• Check for proper greasing and lubrication

5.3 Boom cylinders

• Oil leaks indicated by dirt or oil buildup around the cylinder lip seal

• Oil leaks at hose connections

• Damage to cylinder rods

• Damage or wear to linkage pins (refer to “Pin Inspection Guidelines” for inspection procedure)

5.4 Stick, stick pins, and bearings

• Check for excessive movement in pins and bushings

• Check for proper greasing and lubrication

5.5 Stick cylinder

• Oil leaks indicated by dirt or oil buildup around the cylinder lip seal

• Oil leaks at hose connections

• Damage to cylinder rods

• Damage to wear to linkage pins (refer to “Pin Inspection Guidelines” for inspection procedure)

5.6 Stick heel

• Check for cracks and other structural damage.

5.7 Grapple

• Check for cracks and other structural damage

• Check for proper operation

5.8 Grapple swivel joint

• Check for oil leaks and dirt build-up

5.9 Grapple rotation motor

• Check for oil leaks and dirt build-up

5.10 Tree de-limber (if equipped)

• Check for cracks and other structural damage

• Check for proper operation

• Check for oil leaks and dirt build-up

5.11 Top saw (if equipped)

• Check for proper operation

• Check for loose operation

• Check for blade sharpness

• Check for alignment

4. Scraper Power Pack

4.1 Scraper Power Pack - Lower Level Inspections:

4.1.1 Tires and Rims

Check for:

• Proper inflation

• Cuts, cracks, splits or bruises in the tread or sidewall area. Bumps or bulges may indicate tire separation

• Cracks, pits from corrosion or other visible damage to rims

• Safe tread depth

- Tire cords or exposed fabric

- Uneven tread wear

4.1.2 Final Drives

Check for:

• Oil leakage around the sealing surface between the axle cover and the planetary housing

• Oil leakage around the sealing surface between the planetary housing and the final drive housing

• Oil leakage around the final drive oil drain and fill plugs

• Coolant leakage around the drain/fill plug for the brake coolant

4.1.3 Brake Actuators

Check brake actuators for:

• Leaks around hose connections

• Rubbing, damaged, or worn hoses

• Worn or damaged brake actuator linkage

• Torn dust boots

4.1.4 Differential & Bevel Gear Housing

Check differential oil level:

• If the oil level is low check the following areas for leaks:

- Sealing surface between the axle shaft guard and the bearing retainer

- Sealing surface between the bearing retainer and the differential housing cover

- Sealing surface between the differential housing cover and the differential housing

- Oil leakage around the differential drain plug

- Sealing surface where the oil fill tube connects to the differential housing

- Sealing surface between the pinion bearing retainer and the bevel gear housing

Check for:

• Loose or damaged differential mounting bolts

4.1.5 Driveshaft

Check for:

• Loose or missing U-joint retainer bolts

• Worn U-joints

• Grease leaking from U-joint seals

• Oil leaks indicated by dirt or oil buildup around the pinion lip seal

4.1.6 Torque Converter, Transmission, & Transfer Gear

Check these components and the area around them for:

• Leaks around hose connections

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

• Oil leakage around drain plugs

• Oil or dirt buildup on the mating surfaces and bolted covers

• Driveshaft yoke seals

4.2 Scraper Power Pack - Upper Level Inspections:

4.2.1 Steps & Handrails

Ensure that steps and handrails are in place and check for:

• Damaged, missing, or loose bolts

• Damage to steps or handrails

• Excessive dirt or debris

4.2.2 Hood & Platforms

Check for:

• Structural damage

• Debris or excessive dirt on the steps and service platform

• Loose or damaged bolted access covers

• Proper function of access panel hinges and latches

4.2.3 Power Pack Control Panel

Check for:

• Damaged or inoperable gauges and controls

• Proper function of access panel sliding door and latches

4.2.4 Radiator and Aftercooler

Check for:

• Plugged cores

• Damaged fins

• Plugged or damaged screens

• Rubbing, damaged or worn hoses and tubes

• Leaks around hose connections

• Loose or damaged hose clamps

• Cracked or damaged mounts

4.2.5 Upper & Lower Radiator and Aftercooler Lines

Check for:

• Rubbing, damaged or worn hoses and tubes

• Leaks around hose connections

• Loose or damaged hose clamps

• Improperly secured lines

4.2.6 Radiator Cap

• If the radiator is cool, check the radiator cap gaskets for wear or for damage

4.2.7 Fan, Fan Guard & Shroud

Check for:

• Loose, damaged, or missing bolts

• Loose or damaged wire fan guard

• Loose or damaged fan shroud

• Damaged, cracked, or missing fan blades

4.2.8 Belts & Belt Tensioners

Check for:

• Worn, Cracked or Frayed Belts

• Proper Belt Tension

• Damaged or worn belt tensioner

• Worn or damaged pulleys

• Loose, damaged or missing pulley and belt tensioner mounting bolts

4.2.9 Front Engine Mounts

Check for:

• Worn or damaged rubber isolator ring

• Loose, damaged, or missing mounting bolts

• Structural damage or weld cracks in the mounting frame

4.2.10 Water Pump

Check for:

• Coolant leaks around water pump mounting flange

• Coolant leaks through the weep hole in the water pump housing

• Loose or damaged hose clamps

• Rubbing, damaged, or worn coolant hoses

• Loose or leaking coolant hose connections

4.2.11 Fuel Lines, Fuel Priming Pump, Fuel Filters & Filter Bases

Check for:

• Loose, cracked or damaged mounts

• Rubbing, damaged, or worn fuel lines

• Loose or leaking fuel line connections

• Fuel leaks around the filters and filter bases

4.2.12 Engine Wiring Harness

Check engine harness for the following:

• Loose P-clips / broken wire ties

• Cracked or broken connectors

• Damaged wiring harnesses

• Loose or damaged mounting brackets

4.2.13 Electric Starting Motor

Check for:

• Damage or wear to the wiring harness

• Loose or damaged connections at the electric starting motor and starting motor solenoid

• Proper operation of the electric starting motor

- Listen for grinding or unusual noises when starting the engine

4.2.14 Engine Air Cleaner & Precleaner

Check for:

• Dirt and/or debris in the precleaner

• Loose or damaged hose clamps securing air inlet tube, turbocharger air inlet tube, and dust ejector hose

• Loose or damaged air cleaner cover latches

• Cut or damaged turbo air inlet tube

• Properly functioning air filter restriction indicator sensor

4.2.15 Transmission Oil Filter & Filter Base

Check for:

• Leaks between oil filter base and the torque converter housing manifold

• Oil leakage around the drain plug

• Leaks between the cover and the filter housing

4.2.16 Transmission Pump & Transmission Hydraulic Control Valve

Check for:

• Leaks around hose and tube connections

• Rubbing, damaged or worn hoses

• Rubbing, damaged or worn wiring harnesses or connectors

• Leaks between the sealing surfaces of transmission charge pump, manifold and scavenge pump

4.2.17 Alternator

Check for:

• Rubbing, damaged or worn electrical harnesses

• Loose or corroded wiring connections

4.2.18 Engine Oil Filter and Filter Base

Check for:

• Cracked or damaged mounts

• Rubbing, damaged, or worn lines

• Leaks around the filter and filter base

4.2.19 Turbocharger

Check for:

• Oil leakage around the turbocharger oil lube line and return line

• Dirt tracks which may indicate air inlet or boost air leaks due to worn or damaged hoses

• Loose or damaged hose clamps at the air inlet tube and compressor housing connection

• Black soot around the areas where the turbocharger bolts to theto theexhaust manifold or attaches to the exhaust pipe which would indicate:

- Loose connections at the joints

- Loose or broken mounting bolts

4.2.20 Exhaust Manifold & Muffler

Check for:

• Cracks or other damage to the exhaust manifold housing and muffler

• Black soot indicating a loose, broken, damaged connection around the following sealing surfaces:

- Where the exhaust manifold bolts to the cylinder head

- Clamps and baffles between manifold segments on each cylinder head and muffler

- Where the exhaust manifold bolts to the turbocharger

- Where the exhaust pipe attaches to the turbocharger turbine outlet and to the muffler

4.2.21 Engine Oil Pan

Check for oil on the bottom of the oil pan.

• If oil is found on the pan, inspect the following:

- Check for leaks around the oil pan mounting flange

- Check for leaks around the oil level sensor, drain plug, dipstick tube, turbo lube return & other component connection points in the oil pan

4.2.22 Transmission Oil Tank

Check for:

• Worn or damaged rubber mounts

• Loose tank mounting bolts

• Structural cracks on frame mounting brackets

• Breather for dirt and debris buildup

• Oil lines for leaks and loose or damaged connections

• Sight glass for damage or leaks

• Damaged fill cap or fill cap seal

4.2.23 Batteries & Battery Cables

Check for:

• Corrosion on battery posts and cable connections

• Loose or improperly secure battery cables

• Loose or improperly secured battery hold downs

• Dirt and debris buildup on and around batteries

• Damaged or loose battery cover

• Rubbing, damaged, or worn battery cables

- Pay particular attention to condition of “B+” battery cables and negative cable running from the battery to the disconnect switch