Technical Analysis 1 (TA1) Visual Inspection for Wheel Loaders {0372, 1000, 7000, 753S, 7565} Caterpillar

Wheel Loader

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Introduction

Inspections are the most basic form of condition monitoring. They 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 Inspections" 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

• Check for tubes, hoses, and wiring harnesses not properly secured

- Missing clips and/or wire ties

- O-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 Perform machine inspection preparation

• 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.

• Park the machine in the standard service position

1.3 Perform safety/preparatory inspection

1.4 Download Fault Codes

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

- Electronic Technician (ET)

- Messenger Display (if equipped)

1.5 Check Product Link (https://productsupportglobalcontent.cat.com/cda/files/712700/7/Product%20Link%20Dealer%20Validation.pdf)

• Is machine equipped with Product Link

• Is Product Link registered

• Is Product Link reporting to Vision Link

1.6 Observe engine exhaust colors

• Start the machine and observe exhaust colors:

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

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

- Continuous black smoke could indicate an improper air/fuel mixture

- Continuous gray smoke may indicate a fuel timing problem

1.7 Listen for unusual noises

• Excessive noise coming from engine compartment could indicate:

- Fuel injector damage

- Engine bearing damage

- Valve train damage

• Excessive noise coming from hydraulic pump could indicate either:

- Pump cavitation

- A loose or failed bearing

2.0 Lower-Level Inspections

2.1 Inspect Tires and Rims 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

- Tread worn down to the built-in wear indicators

- Tire cords or exposed fabric

- Uneven tread wear

2.2 Inspect Final Drives and Wheel Spindles:

Check final drive oil level

• If equipped, check the magnetic plug for metal particles

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

- Sealing surface between the axle cover and the final drive planet carrier

- Sealing surface between the planetary housing and the final drive housing

- Duo-cone seal located between the final drive housing or wheel spindle and the axle housing

- Oil leakage around the drain/fill plug

2.3 Inspect Front and Rear Differentials:

Check differential oil level:

• If equipped, check the magnetic plug for metal particles

• Check for loose or damaged mounting axle bolts

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

- Sealing surface between the axle housing and the differential carrier group

- Sealing surface between the intermediate housing and the differential housing

- Sealing surface between the differential housing and the pinion housing

- Sealing surface between the pinion housing and the driveshaft

- Oil leakage around the drain and fill plugs

2.4 Inspect Front, Center, and Rear Drive Shafts for:

• Loose or missing U-joint retainer bolts

• Worn or loose U-joints or drive shaft spline

• Grease leaking from U-joint seals or from drive shaft spline seal; grease leakage in these areas would indicate possible seal damage

2.5 Inspect Center Support Bearing for:

• Loose or damaged mounting bolts

• Damaged grease line

• Worn bearing

2.6 Inspect Torque Converter, Transmission, and Transfer Gear Box Compartment\

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

Check for oil or dirt buildup on the bottom surface of the transmission guard

• Oil on the guard would indicate a leak from components located above the guard; remove the transmission guard and inspect components for leaks

2.7 Inspect Hydraulic Pump Compartment for:

• Leaks around hose connection points

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

• Loose or damaged hose clamps on pump suction lines

2.8 Inspect Upper and Lower Hitch Pins/Bore for

• Loose or broken flange bolts

• Irregular-shaped pin bores

• Broken or damaged grease lines or grease fittings

2.9 Inspect Main Machine Frame for:

• Damage to frame

• Structural cracks

• Cracked welds

3.0 Middle-Level Inspections:

3.1 Inspect 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

3.2 Inspect Work Lights/Hazard Lights:

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

• Proper operation

• Cracked or broken lenses

• Damaged wiring harnesses

3.3 Inspect Cab Mounts for:

• Loose or damaged bolts

• Worn or damaged rubber mounts

3.4 Inspect Steering Control Valve, Steering Neutralizer Valve, Brake Valve, and HMU for:

• Leaks around hose connections

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

3.5 Inspect Implement Control Valve for:

• Leaks around hose and control valve components connection points

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

3.6 Inspect Radiator, Oil Cooler, Condenser, and Aftercooler for:

• Plugged cores

• Plugged screens

• Damaged fins

3.7 Inspect Oil Cooler and Condenser Lines for:

• Leaks around hose connections

• Rubbing, cracked, or damaged hoses

• Loose connections

• Improperly secured hoses

3.8 Inspect Hood and Platform for:

• Improper function of hood raise cylinder

• Debris or excessive dirt on service platform ventilation screen

• Loose or damaged ventilation screens

• Improper function of side access panels and latches

• Broken or damaged grease lines or grease fittings

3.9 Inspect Battery and Battery Cables:

• Check battery posts and cables for corrosion

• Check the battery hold-down for proper function and tightness

3.10 Inspect Fenders for:

• Bent or damaged fenders that interfere with tires

• Loose or missing mounting bolts

• Properly operating latches and hinges (if equipped)

• Missing or damaged prop rod

3.11 Inspect Lower Radiator and Oil Cooler Hoses for:

• Rubbing, cracked, or damaged hoses

• Loose or damaged hose clamps

• Loose connections

• Improperly secured hoses

3.12 Inspect Engine Oil Pan:

Check for oil accumulation on the bottom of the oil pan; if oil is found, inspect the following:

• Check for leaks around the oil pan mounting flange

• Check for leaks around the oil level sensor, drain valve, and the dipstick tube

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 window 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 Pump(s):

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:

• Check for oil leakage around the turbocharger oil line

• Check for loose or damaged hose clamps on air inlet tube and compressor housing

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

- A loose connection at the joint

- Loose or broken mounting bolts

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 for oil leaks around air condition compressor clutch

• Check hydraulic fan drive motor and lines for leaks

• Check belt drives for:

- Worn, cracked, or broken belts

- Proper belt tension

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 rod & cylinder lip seals

• Oil leaks at hose connections

• Damage to cylinder rods

• Damage or wear to linkage pins

- Refer to “Linkage Pin Inspection Guidelines” for the pin 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 Tilt Cylinder for:

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

• Oil leaks at hose connections

• Damage to cylinder rods

• Loose, damaged, or worn pin joints

- Refer to “Linkage Pin Inspection Guidelines” for the pin inspection procedure

5.4 Inspect Area where Tilt Lever attaches to Lift Arm 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 the pin inspection procedure

5.5 Inspect Bucket Linkage for:

• Loose or broken flange mounting bolt

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

• Loose or missing pin retainer bolts

• Irregular-shaped pin bores

5.6 Inspect Bucket Wear Plates for:

• Excessive wear

5.7 Inspect Bucket Side Cutters for:

• Excessive wear

• Loose, damaged, or missing bolts

5.8 Inspect Bucket Edges, Tips, and Adapters:

Check base edges for:

• Cracks beside adapters and corner welds

• Cracks on top and bottom of rear weld

Check for excessive wear on the bucket tips

• Tips worn through on the bottom or cracked in the pocket area should be replaced

Check for damage to the bucket tip adapters

• Badly worn bottom straps that are worn into bottom cavity should be replaced

Check for damaged or missing retainer pins

• Tap lightly on each pin; replace pin if it moves easily

Performance Inspection

Hydraulic Performance Checks

Implement Cycle Time - Check

Lift & Tilt Cylinder Drift - Check

Brake Performance Checks

Steering Performance Checks

Command Control Steering Time - Check

HMU Steering Time - Check