Technical Analysis 1 (TA1) Visual Inspection for Track-Type Skidders {0372, 1000, 7000, 753S, 7565} Caterpillar

Track-Type Skidder

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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 effectively 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 Lower-Level Inspection

Refer to "2.0 Lower-Level Inspection" section in "Inspection Reference" for more information for performing lower-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

• Finds overlooked problems

• Enables scheduled maintenance and repairs

• Lowers owning and operating costs

Guidelines

Wiring Harness Inspection Guidelines

Check for:

• Tubes, hoses, and wiring harnesses rubbing against:

- One another

- Sharp corners

- Bolt heads

• Tubes, hoses, and wiring harnesses not properly secured

- Missing clips and/or wire ties

- P-clips not attached

Harness Connector Inspection Guidelines

Check for connectors:

• Not properly secured in place

• Rubbing against machine frame

• Rubbing against sharp edges

Implement Linkage Pin Inspection Guidelines

Check for:

• Loose or broken flange mounting bolt

• Elongated bolt hole in flange (hole is located behind pin retaining bolt)

• Loose or missing pin retainer bolts

• Irregular shaped pin bores

Hydraulic Cylinder Inspection Guidelines:

Check for:

• 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)

1.0 Inspection Preparation

1.1 Check with customer for operator complaints

1.2 Prepare the machine for the inspection

• Be sure that the area is free of personnel. Make sure no one is underneath the machine, around the machine, or on the machine.

• Turn the key to the ON position to check fluid levels using the monitor. If fluid levels cannot be checked using the monitor, manually check the engine oil, hydraulic oil, and coolant levels. If necessary, add engine oil, hydraulic oil, or coolant to reach minimum level for each system

• Park the machine in the standard service position

1.3 Perform safety/preparatory inspection

1.4 Download machine fault codes

• Download machine fault codes using either of the following methods:

- Electronic Technician (ET)

- Machine monitor

1.5 Check Product Link

• Is machine equipped with PL?

• Is PL activated?

• Is PL functioning properly?

1.6 Observe engine exhaust colors

• Start the machine and observe exhaust colors:

- White smoke after initial startup could indicate coolant in the engine cylinder

- Blue smoke during startup may indicate oil in the engine cylinder

- Black smoke during startup may indicate plugged air filter

- Continuous black smoke could indicate improper air/fuel mixture

- Continuous gray smoke may indicate fuel timing problem

1.7 Listen for unusual noises

• Excessive noise coming from hydraulic pump could indicate either:

- Pump cavitation

- A loose or failed bearing

• Excessive noise coming from engine compartment could indicate:

- Fuel injector knocks

- Engine bearing damage

- Valve train damage

2.0 Lower-Level Inspection

2.1 Final Drive and Sprocket Inspection

Check final drives for leaks in the following areas:

• Sealing surface between the axle cover and the final drive cover

• Sealing surface between the final drive cover and the ring gear

• Duo-cone seal located behind the sprocket

• Drain and fill plugs

Inspect the sprockets for:

• Broken or chipped teeth

• Sharp edges on sprocket teeth which indicate excessive sprocket wear

• Loose or missing sprocket mounting bolts

2.2 Carrier Roller Inspection

Check for:

• Oil leakage in the following areas:

- On the sealing surface between the front cover and the roller

- From the duo-cone seal located on the back side of the carrier roller

• Loose, missing, or damaged mounting bolts

• Excessive wear on the surface where the track link rides on the carrier roller

2.3 Track Roller Inspection

Check for:

• Oil leakage from the following areas:

- The duo-cone seals located on the front and back sides of the track roller

- Each end of the track roller shaft, leakage in this area would indicate the O-ring seal located on the track roller shaft may worn or damaged

• Excessive wear on the surface where the track link rides on the track roller

2.4 Track Roller Bogie Inspection

Check for:

• Missing retaining rings on each side of the major bogies

• Leaking bogie cartridge pins

• Minor bogie cartridge pin covers worn significantly on top and bottom

• Roller caps and pins for proper shimming and loose/damaged fasteners

- If machine is still warm from operation, check for hot pins

2.5 Front and Rear Idler Inspection

Check for:

• Oil leakage from the following areas:

- From the duo-cone seals located on the front and back side of the idler

- At each end of the track idler shaft, leakage in this area would indicate the O-ring seal located on the shaft may be worn or damaged

• Excessive wear on the surfaces on both sides of the idler where the track link rides on the idler

• Loose, damaged, or missing bearing cap mounting bolts

2.6 Track Guide Inspection

Check for:

• Damaged, missing, or loose track roller guide mounting bolts

• Excessive damage or wear to track guides (inside and outside)

2.7 Track Shoe Inspection

Check for:

• Damaged, missing, or loose track bolts

• Damaged or worn track shoes

2.8 Track Link/Pin/Bushing Inspection

Check for:

• Excessive wear on contact surface of track link

• Excessive noise in the track during machine operation

- If excessive noise is noticed, check for temperature variances between the pins. To do this, touch the end of the pins with your hand or use an infrared thermometer. Large temperature variances may indicate a dry joint in the link.

2.9 Track Roller Frame Inspection

• Check for:

- Link wear grooves on top of the roller frames

- Cracks on the rear track roller frame weld seams between the pivot shaft and guide bores

- Oil leakage from under the chrome bearing sleeve

• You should also check if the rear roller frame seal has worn through the chrome surface of the bearing sleeve.

2.10 Track Equalizer Bar Inspection

Check for:

• Oil leakage around the equalizer end pins

• Cracked rubber and/or missing portions of rubber in the equalizer bar pads

• Loose or damaged mounting bolts

• Irregular-shaped center pin bores

2.11 Pivot Shaft Inspection

Check for oil leaks in the following areas:

• Sealing surface between the cover plate and the track roller frame

• Sealing surface between the main frame and the track roller frame

• Lubrication lines from the remote mounted reservoir (if equipped)

2.12 Bottom Guard Inspection

Check for:

• Oil leaks indicated by dirt and oil buildup on the underneath surface and edges of the bottom guards; oil buildup in this area would indicate possible leaks from components located above the guard

• Loose, damaged, or missing bolts

• Damaged hinges

• Structural damage or cracks around welded joints

3.0 Middle-Level Inspections:

3.1 Step and Handrail Inspection

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

3.2 Work Light Inspection

Check road lights, turn signals, hazard flashers, work lights, and other lights for:

• Proper operation

• Cracked or broken lenses

• Damaged harnesses or electrical connectors

• Loose or damaged mounting brackets and fasteners

3.3 Hood, Platform, and Access Door Inspection

Check :

• Hood mounts, access doors, seals, door props, hinges, and latches for damage and proper operation

• Hood, ventilation screens, and service platform for debris or excessive dirt

• Hood mounts for:

- Loose or damaged bolts

- Wear or damage to rubber mounts

3.4 Fan Guard and Fan Inspection

Check for:

• Loose, damaged, or missing bolts

• Damaged wire fan guard

• Damaged fan blade

• Oil leaks from fan motor and hydraulic lines

3.5 Radiator, Condenser, Oil Cooler, and Aftercooler Inspection

Check for:

• Fluid leaks

• Plugged cores

• Plugged screens

• Damaged fins

3.6 Radiator Cap Inspection

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

3.7 Upper and Lower Radiator Hose and Oil Cooler Hose Inspection

Check for:

• Rubbing, cracked, or damaged hoses

• Loose or damaged hose clamps

3.8 Aftercooler Line Inspection

Check for:

• Rubbing, cracked, or damaged hoses

• Loose or damaged hose clamps

3.9 Air Cleaner and Pre-Cleaner Inspection

Check for:

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

• Loose or damaged hose clamps on turbo compressor air inlet tube and pre-cleaner vacuum hose

• Rubbing, cracked, or damaged hoses

3.10 Cylinder Head and Valve Cover Inspection

Check for:

• Oil and dust buildup around:

1. Crankcase Breather

2. Valve cover sealing surface, this would indicate:

- Loose connection at the joint

- Damaged gasket or seal

• Fuel leaks around and below the protective guard located above the fuel lines (if equipped), leakage in this area would indicate a damaged fuel line or fuel injector

3.11 Turbocharger Inspection

Check for:

• Black soot around the sealing surface where the exhaust manifold bolts to the engine block and to the turbocharger turbine, this would indicate:

- Loose connection at the joint

- Loose or broken mounting bolts

• Oil leakage around the turbocharger oil line

• Loose or damaged hose clamp on air inlet tube

3.12 Exhaust Manifold Inspection

Check for:

• Cracks or other damage in the manifold housing

• Black soot around the sealing surface where the exhaust manifold bolts to the engine block and to the turbocharger turbine which would indicate:

- Loose connection at the joint

- Loose or broken manifold bolts

3.13 Pulleys, Belts, and Compressor Clutch Inspection

Check for:

• Worn, cracked, or broken belts

• Proper belt tension

• Oil leaks around air conditioning compressor clutch

3.14 Water Pump Inspection

Check for:

• Coolant leaks around water pump mounting flange

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

3.15 Engine Wiring Harness Inspection

• Check Wiring harnesses for loose or damaged wires, connectors, and sensors

- Refer to Wiring Harness Inspection Guidelines and Harness Connector Inspection Guidelines for inspection procedures

3.16 Fuel Lines and Fuel Pump Inspection

Check fuel priming pump, fuel lines, and fuel injection pump for:

• Damaged, rubbing, or worn fuel lines

• Loose connections

4.0 Upper-Level Inspections:

4.1 Inspect Cab Exterior for:

• Bent or damaged cab structure

• Cracked or broken glass

• Damaged or missing mirrors

• Worn or broken windshield wiper arm or wiper blade

4.2 Inspect Cab Interior for:

• Excessive dirt in cab air filter

• Proper function of seat and seat belt

• Wear or damage to seat belt

• Seat belt replacement date

• Proper function of door and latches

• Worn or broken window latches or slides

• Damaged or inoperable gauges and controls

4.3 Inspect Pre-cleaner and Air Cleaner for:

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

• Loose or damaged hose clamps on the air inlet tube

4.4 Inspect Upper Radiator, Air Inlet, Oil Cooler, and Aftercooler Lines for:

• Rubbing, cracked, or damaged hoses

• Loose or damaged hose clamps

4.5 Inspect Radiator Cap:

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

4.6 Inspect Water Pump for:

• Coolant leaks around water pump mounting flange

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

4.7 Inspect Fuel Lines and Fuel System Pumps:

Check fuel priming pump, secondary fuel filter, and fuel injection pump for:

• Damaged, rubbing, or worn fuel lines or hydraulic lines

• Loose connections

4.8 Inspect Exhaust Manifold:

• Check for cracks or other damage in the manifold housing

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

- A loose connection at the cylinder head joint

- Loose or broken manifold bolts

4.9 Inspect Turbocharger:

• Black soot around the sealing surface where the exhaust manifold bolts to the engine block and to the turbocharger turbine, this would indicate:

- Loose connection at the joint

- Loose or broken mounting bolts

• Oil leakage around the turbocharger oil line

• Loose or damaged hose clamp on air inlet tube

4.10 Inspect Cylinder Head and Valve Cover for:

Oil and dust buildup around the valve cover sealing surface which would indicate:

• A loose connection at the joint

• Damaged gasket or seal

4.11 Inspect Belts, Pulleys, Compressor Clutch, and Fan Motor:

• Check belt drives for:

- Worn, cracked, or broken belts

- Proper belt tension

• Check for oil leaks around air condition compressor clutch

• Check hydraulic fan drive motor and lines for leaks

4.12 Inspect Cooling Fan, Fan Guard, and Shroud for:

• Loose, damaged, or missing bolts

• Loose or damaged wire fan guard

• Loose or damaged fan shroud

• Damaged, cracked, or missing engine fan blades

4.13 Inspect Engine Wiring Harness for:

• Loose or damaged wires, connectors, and sensors

4.14 Inspect Engine Mounts for:

• Loose or damaged bolts

• Cracked or damaged washer

• Cracked or damaged mount brackets

• Wear, damage, or cracking of upper and lower rubber support pads

- There should be no metal-to-metal contact

5.0 Implement/Attachment Inspections

5.1 Inspect Lift Cylinder for:

• 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 Linkage Pin Inspection Guidelines for inspection procedure

5.2 Inspect Area where Lift Arm attaches to frame:

Check lift arms for:

• Structural damage or cracks around welded joints

Check pin joints for:

• Damage or wear to pins/bores

• Loose, damaged, or missing retainer bolts

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

5.3 Inspect Decking Blade for:

• Loose, damaged, or worn pin joints

- Refer to Linkage Pin Inspection Guidelines for inspection procedure

5.4 Inspect Arch Cylinder for:

• Oil leaks indicated by dirt or oil buildup around the cylinder pin joint lip seals

• Loose, damaged, or missing retainer bolts

• Loose, damaged, or worn pin joints

- Refer to Linkage Pin Inspection Guidelines for inspection procedure

5.5 Inspect Boom Cylinder for:

• Oil leaks indicated by dirt or oil buildup around the cylinder pin joint lip seals

• Loose, damaged, or missing retainer bolts

• Loose, damaged, or worn pin joints

- Refer to Linkage Pin Inspection Guidelines for inspection procedure

5.6 Inspect Tong Cylinder for:

• Oil leaks indicated by dirt or oil buildup around the cylinder pin joint lip seals

• Loose, damaged, or missing retainer bolts

• Loose, damaged, or worn pin joints

- Refer to Linkage Pin Inspection Guidelines for inspection procedure

5.7 Inspect Fairlead Roller for:

• Excessive wear

• Loose, damaged, or missing bolts

5.8 Inspect Grapple for:

• Cracks on welds

• Cracks on top and bottom of welds

• Loose, damaged, or worn pin joints

5.9 Inspect Hydraulic Rotator for:

• Oil leaks indicated by dirt or oil buildup

5.10 Inspect Grapple Tong

5.11 Inspect Grapple Snubber

5.12 Inspect Grapple Boom for:

• Cracks on welds

• Loose, damaged, or missing retainer bolts

5.13 Inspect Grapple Arch for:

• Cracks on welds

• Loose, damaged, or missing retainer bolts

5.14 Inspect Winch for:

• Oil leaks indicated by dirt or oil buildup

• Loose, damaged, or missing bolts

Performance Checks

Hydraulic Performance Checks

Lift Cylinder (Decking Blade) Cycle Time - Check

Lift Cylinder (Decking Blade) Drift - Check

Grapple Cylinder Speed - Check

Steering Performance Checks

Steering Turn Diameter Check