Technical Analysis 1 (TA1) Visual Inspection For Wheel Loaders

2/7/23, 4:29 PM SIS 2.
Technical Analysis 1 (TA1) Visual Inspection for Wheel Loaders {0372, 1000, 7000, 753S,
2023/01/12
7565} (M0065478-02)
SMCS - 0372, 1000, 7000, 753S, 7565 i09703116

Wheel Loader
All PPI
Introduction 202 -0005
3 /
20: 02/0 D05 C
Inspections are the most basic form of condition monitoring. They are easy to do and surprisingly effective
2
at helping you spot equipment health issues. Proactive monitoring and analysis of equipment information
M0 9:09- 7
will allow Dealers to effectively intervene before problems occur.
latest specification values. 0 6

© 2 547 4:00 0
Note: Before adjusting product settings to comply with listed baseline TA1 values, consult SIS for the
Table 1
023 8
Serial Number:
Cat Inspector: Temperature:
Model:
erp Work Order: Time:
Engine S/N:
illa
SMU: Date:
Manufacture:
r In Unit Location:
c.
Note: Review Machine & S.O.S. History and check for Active Service Letters prior to inspection.
Status of the Machine(1)
The status recommendation of your Wheel Loader is:
(1)
N = Normal, D = Down Machine, M = Monitor/Needs Attention
Creating an Electronic Copy

Use the following procedure to create an editable electronic copy from SIS web.
1. Click format to print.
2. Save the document as an HTML format.
3. Open the document with Microsoft Word.
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.
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2/7/23, 4:29 PM SIS 2.0
Table 2
Sl.No. Status(1) 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
Check Product Link
Is machine equipped with Product Link
1.5
Is Product Link activated
Is Product Link functioning properly
1.6 Observe engine exhaust colors
Listen for unusual noises (hydraulic pumps, engine, transmission,
1.7
and axles)
(1)
N = Normal, M = Monitor, A = Action, Blank = Not Applicable
2.0 Lower-Level Inspection

Refer to "2.0 Lower-Level Inspections" section in "Inspection Reference" for more information for
performing lower-level inspection.
Table 3

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
(1)
3.0 Middle-Level Inspection

Refer to "3.0 Middle-Level Inspections:" section in "Inspection Reference" for more information for
performing middle-level inspection.
2/7/23, 4:29 PM SIS 2.0
Table 4

3.1 Steps and handrails
3.2 Work light/hazard lights
3.3 Cab mounts
Steering control valve, steering neutralizer valve, brake valve, and
3.4
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
(1)
4.0 Upper-Level Inspection

Refer to "4.0 Upper-Level Inspections:" section in "Inspection Reference" for more information for
performing upper-level inspection.
Table 5

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
2/7/23, 4:29 PM SIS 2.0
4.14 Engine mounts

(1)
5.0 Implement/Attachment Inspection

Refer to "5.0 Implement/Attachment Inspections:" section in "Inspection Reference" for more information
for performing implement/attachment inspection.
Table 6

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
(1)
6.0 Site Conditions

Table 7
Ambient Temperature
NORMAL: −18 to 32°C (0 to 90°F)
6.1
MONITOR: 32 to 46°C (90 to 115°F) or −18° to -29°C (0 to -20°F)
ACTION: Above 46° C (115° F) or Below −29° C (−20° F)
Altitude
NORMAL: 0 to 1524 m (0 to 5000 ft)
6.2
MONITOR: 1524 to 3048 m (5000 to 10000 ft)
ACTION: Above 3048 m (10000 ft)
Haul Road Grade
NORMAL: Flat
6.3
MONITOR: Mild
ACTION: Steep
2/7/23, 4:29 PM SIS 2.0
Haul Road Condition

6.4 NORMAL: Positive Banking, Gradual Turns, Good Erosion Control
ACTION: Negative Banking, Sharp Turns, Poor Erosion Control
Humidity
NORMAL: Below 25%
6.5
MONITOR: 25 to 60%
ACTION: Above 60%
Air Quality
NORMAL: No Dust
6.6
MONITOR: Light Dust
ACTION: Heavy Dust
Underfoot Condition
NORMAL: Dry Flat Surface
6.7
MONITOR: Moderate Grades, Mixture of Muddy / Dry Surfaces
ACTION: Steep Grades, Muddy, Snow, Ice
Machine Utilization
6.8 NORMAL: 0 to 10 Hours
ACTION: Above 10 hours
Equipment Role
NORMAL: Utility
6.9
MONITOR: Support
ACTION: Production
Working Material
NORMAL: Uncompacted, Low Abrasion
6.10
MONITOR: Moderately Compacted, Moderate Abrasion
ACTION: High Abrasion, Compacted, Dense
Maintenance Practices
NORMAL: Excellent
6.11
MONITOR: Good
ACTION: Poor
6.12 Primary Industries
(1)
Inspection Reference
Inspection Benefits:
2/7/23, 4:29 PM SIS 2.0
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
2/7/23, 4:29 PM SIS 2.0
PPI
Hydraulic Cylinder Inspection Guidelines:
Check for:
-
202 0005
Oil leaks indicated by dirt or oil buildup around the cylinder lip seal
3 /
20: 02/0 D05
Oil leaks at hose connections C
2
M0 9:09- 7
Damage to cylinder rods
0 6 0
Damage or wear to linkage pins (refer to "Pin Inspection Guidelines" for inspection procedure)
© 2 547 4:00
1.0 Inspection Preparation
023 8
1.1 Check with customer for operator complaints
Cat
erp
1.2 Perform machine inspection preparation
illa
Be sure that the area is free of personnel. Make sure no one is underneath the machine, around the
machine, or on the machine.
r In
c.
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:
2/7/23, 4:29 PM SIS 2.0
- 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
2/7/23, 4:29 PM SIS 2.0
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\
2/7/23, 4:29 PM SIS 2.0
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
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
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2/7/23, 4:29 PM SIS 2.0
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:
3.5 Inspect Implement Control Valve for:
Leaks around hose and control valve components connection points
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:
Rubbing, cracked, or damaged hoses
Loose connections
2/7/23, 4:29 PM SIS 2.0
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:
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:

2/7/23, 4:29 PM SIS 2.0
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:
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):
2/7/23, 4:29 PM SIS 2.0
Check fuel priming pump, secondary fuel filter, and fuel injection pump for:
Damaged, rubbing, or worn fuel lines or hydraulic lines
Loose connections PPI

4.8 Inspect Exhaust Manifold: -
202 0005
3 /
20: 02/0 D05 C
Check for cracks or other damage in the manifold housing
2
M0 9:09- 7
Black soot around the sealing surface where the exhaust manifold bolts to the engine block would
indicate:
0 6
© 2 547 4:00
- A loose connection at the cylinder head joint
0
- Loose or broken manifold bolts
023 8
4.9 Inspect Turbocharger:
Cat
erp
Check for oil leakage around the turbocharger oil line
illa
r In
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: c.
- 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

2/7/23, 4:29 PM SIS 2.0
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 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
2/7/23, 4:29 PM SIS 2.0
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
Loose, damaged, or worn pin joints
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
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:
2/7/23, 4:29 PM SIS 2.0
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
Table 8
Status(1) Description Specification Actual Comments
Lift Raise
Lift Lower
Float
Tilt Back
Dump
(1)
Lift & Tilt Cylinder Drift - Check

Table 9

Lift Cylinder
Tilt Cylinder
(1)
Brake Performance Checks

Table 10
2/7/23, 4:29 PM SIS 2.0
Brake Accumulator - Test (Test from OMM)

Parking Brake - Test (Test from OMM)
(1)
Steering Performance Checks

Command Control Steering Time - Check
Table 11

Left Steering Time (High Idle)
Right Steering Time (High Idle)
Left Steering Time (Low Idle)
Right Steering Time (Low Idle)
Left/Right Time Difference (Max)
(1)
HMU Steering Time - Check

Table 12

Left Steering Time (High Idle)
Right Steering Time (High Idle)
Left Steering Time (Low Idle)
Right Steering Time (Low Idle)
Left/Right Time Difference (Max)
(1)
PPI-0005CD05
2023/02/07
20:28:48-04:00
i06523910
© 2023 Caterpillar Inc.

Technical Analysis 1 (TA1) Visual Inspection For Wheel Loaders

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Technical Analysis 1 (TA1) Visual Inspection For Wheel Loaders

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Available Formats

2/7/23, 4:29 PM SIS 2.

SMCS - 0372, 1000, 7000, 753S, 7565 i09703116

latest specification values. 0 6

Creating an Electronic Copy

1. Click format to print.

2. Save the document as an HTML format.

3. Open the document with Microsoft Word.

Sl.No. Status(1) Description Comments

2.0 Lower-Level Inspection

Sl.No. Status(1) Description Comments

3.0 Middle-Level Inspection

Sl.No. Status(1) Description Comments

4.0 Upper-Level Inspection

Sl.No. Status(1) Description Comments

4.14 Engine mounts

5.0 Implement/Attachment Inspection

Sl.No. Status(1) Description Comments

6.0 Site Conditions

Haul Road Condition

Minimizes downtime through scheduled maintenance

Locates potential problems

Finds overlooked problems

Enables scheduled maintenance and repairs

Lowers owning and operating costs

- Missing clips and/or wire ties

- O-clips not attached

Harness Connector Inspection Guidelines

Not properly secured in place

Rubbing against machine frame

Rubbing against sharp edges

Implement Linkage Pin Inspection Guidelines

Loose or broken flange mounting bolt

Loose or missing pin retainer bolts

Irregular shaped pin bores

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

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:

- 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:

- A loose or failed bearing

2.0 Lower-Level Inspections

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: