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

Backhoe 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.

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 harness 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.

• 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 hydraulic pump could indicate either:

- Pump cavitation

- A loose or failed bearing

• Excessive noise coming from engine compartment could indicate:

- Fuel injector damage

- Engine bearing damage

- Valve train damage

2.0 Lower-Level Inspections

2.1 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

2.2 Fenders

• Loose or missing mounting bolts

• Bent or damaged fenders and mounting brackets

- Potential interference with tires

2.3 Steering Arms and Kingpins

• Structural damage

• Excessive play and loose or missing retainer plates in kingpins

• Improper lubrication and damaged or missing grease fittings

• Damaged, missing, or improperly adjusted stop bolt

2.4 Steering Cylinders, Tie Rods, and Linkages

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

• Oil leaks at hose connections

• Damage to cylinder rods - Refer to “Hydraulic Cylinder Inspection Guidelines” for procedure

• Damage or wear to linkages, fasteners, and grease fittings

- Check for cracked or blown out grease boots

- Check tie rod adjustment stop nuts

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

2.5 Front Differential and Steering Axle

Check differential oil level

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

- Sealing surface between the axle housing and the differential housing

- Sealing surface between the differential carrier flange and the steering axle housing

- Sealing surface between the drive shaft and differential carrier

- Oil drain and fill plugs

• Check axle for structural damage or weld cracks

- Axle oscillation joint for loose or missing pin retaining bolt or elongation of the hole in the pin tag

- Axle oscillation stops for damage or improper adjustment

2.6 Engine Oil Pan

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

• Leaks around the oil pan mounting flange

• Leaks around the oil level sensor, drain valve, and the dipstick tube

• Cracks and/or leaks in the oil pan casting

2.7 Engine Mounts

• Loose or damaged bolts

• Cracked or damaged washer

• Cracked or damaged mount brackets

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

- There should be no metal-to-metal contact

2.8 Fuel System Lines, Pumps, and Filter Bases

• Damaged, rubbing, or worn fuel lines

• Loose hose connections

• Rubbing, damaged, or worn wiring harnesses and connectors

2.9 Hydraulic Pump

• 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

• Rubbing, damaged, or worn wiring harnesses or connectors

2.10 Transmission, Torque Converter, and Transfer Gears

• Leaks around hose connections

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

• Check for oil or dirt buildup at the following locations:

- Transmission output shaft

- Sealing surface between the transmission housing and the torque converter

- Sealing surface between the back and front halves of the transmission case

- Drain and fill plugs

2.11 Transmission Mounts

• Loose or damaged bolts

• Cracked or damaged washer

• Cracked or damaged mount brackets

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

2.12 Loader Implement Control Valve

• Leaks around connection points for hose and control valve components

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses and connectors

2.13 Front Drive Shaft

• Loose or missing U-joint retainer bolts

• Worn or loose U-joints or drive shaft spline. There should be no metal-to-metal contact

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

2.14 Rear Drive Shaft and Parking Brake

Check Drive Shaft 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

Check Parking Brake for:

• Proper operation

• Excessive pad or rotor wear

• Loose or damaged caliper mechanism or cable

2.15 Rear Differential and Axle

Check the following areas for leaks:

• Sealing surface between the axle housing and the differential housing

• Sealing surface between the drive shaft and differential carrier

• Oil drain and fill plugs

• Hoses and connectors to service brake and differential lock

Check for:

• Loose or damaged axle mounting bolts

2.16 Final Drives and Wheel Spindles

Check final drive oil level: (Refer to OMM for procedure)

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

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

• Duo-cone seal located between the axle housing and the back of the final drive housing

• Oil leakage around the drain and fill plugs

2.17 Main Machine Frame

• Damage to frame

• Structural cracks

• Cracked welds

3.0 Middle-Level Inspections:

3.1 Work Lights

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

• Proper operation

• Cracked or broken lenses

• Damaged wiring harnesses

3.2 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

3.3 Batteries and Battery Cables

• Battery posts and cables for corrosion or damage

• For rubbing, damaged, or worn cables

• Battery holds down for proper function and tightness

3.4 Cab Mounts

• Loose or damaged mounting bolts

• Cracked or damaged washers

• Cracked or damaged mount brackets

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

- There should be no metal to metal contact

3.5 Backhoe Implement Control Valve

• Leaks around connection points for hose and control valve components

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses and connectors

3.6 Cab Exterior

• Bent or damaged cab structure

• Cracked or broken glass

• Damaged or missing mirrors

• Worn or broken window wiper arms or wiper blades

4.0 Upper-Level Inspections:

4.1 Radiator/Oil Cooler Screen

• Debris on the screen; clean if necessary

• Holes and tears in the screen

4.2 Hood and Platform

Check gas struts and hinges for :

• Proper function

• Loose or damaged linkages

Check hood ventilation screens and air inlet port for :

• Plugging with debris or excessive dirt

• Loose, missing, or damaged screens

Check hood latch for damage or improper operation

Check hood air inlet port for:

• Plugging with debris or excessive dirt

• Loose, missing, or damaged screens

• Loose, missing, or damaged baffle seal on air cleaner assembly

4.3 Radiator Cap

If the radiator is cool, check O-ring seals on the expansion tank cap for wear or damage

4.4 Radiator, Oil Cooler, and Condenser

• Leaks around hose connections

• Rubbing, cracked, and damaged hoses

• Loose connections

• Improperly secured hoses

• Plugged cores

• Plugged screens

• Damaged fins

4.5 Cooling Fan, Fan Guard, and Shroud

• Loose, damaged, or missing bolts

• Loose or damaged wire fan guard

• Loose or damaged fan shroud

• Damaged, cracked, or missing engine fan blades

4.6 Pulleys, Belts, Water Pump, Compressor Clutch, Alternator, and Fan Drive

Check belt drives for:

• Worn, cracked, or broken belts

• Proper belt tension

Check for oil leaks around air condition compressor clutch

Check water pump for:

• Coolant leaks around water pump mounting flange

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

4.7 Cylinder Head and Valve Cover

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

• Loose connection at the joint

• Damaged gasket or seal

4.8 Turbocharger

• Oil leakage around the turbocharger oil line

• 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 which would indicate:

- Loose connection at the joint

- Loose or broken mounting bolts

4.9 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 would indicate:

- Loose connection at the cylinder head joint

- Loose or broken manifold bolts

4.10 Air Cleaner

• Loose or damaged hose clamps on securing turbocharger air inlet tube

• Improperly sealing air inlet baffles

- Look for tears, cracks, or other damage which would prevent a tight seal between the hood and filter housing baffles

- Look for signs of "dirt tracks" as an indication of air leaks

4.11 Cab Interior

• 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

5.0 Implement/Attachment Inspections:

5.1 Loader Lift Cylinder

Refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure

• 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 Loader Lift Arm

Refer to “Linkage Pin Inspection Guidelines” for procedure

Check lift arms for:

• Structural damage or cracks around welded joints

Check pin joints for:

• Blown out pin joint lip seals indicated by dirt and grease buildup around the pin joints

• Loose, damaged, or missing snap ring retainers

• Damage to lift arm position sensor at the lift arm pivot linkage

• Loose, damaged, or worn pin joints

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

5.3 Loader Tilt Cylinder

Refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure

• Damaged pin joint lip seals indicated by dirt and grease buildup around the pin joints

• Oil leaks indicated by dirt or 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 procedure

5.4 Loader Tilt Levers

• Damaged pin joint lip seals indicated by dirt and grease buildup around the pin joints

• Loose, damaged, missing snap ring pin retainers

• Loose, damaged, or worn pin joints

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

5.5 Loader Bucket Linkage

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

• Blown out pin joint lip seals indicated by dirt and grease buildup around the pin joints

• Loose or missing snap ring pin retainers

• Irregular shaped pin bores

5.6 Loader Bucket

• Cracks on base edges:

- Beside adapters and corner welds

- On top and bottom of rear weld

• Loose, damaged, or missing fasteners on base edge and side cutters

• Excessive wear on base edge, side cutters, and wear plates

• Excessive wear on the bucket tips

- Replace tips that worn through on the bottom or cracked in the pocket area

• Damage to bucket tip adapters

- Replace badly worn bottom straps that are worn into bottom cavity

• Damaged or missing retainer pins

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

5.7 Stabilizer Cylinders

Refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure

• Oil leaks indicated by dirt or 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 inspection procedure

5.8 Stabilizers

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

Check lift arms for:

• Structural damage or cracks around welded joints

Check pin joints for:

• Blown out pin joint lip seals indicated by dirt and grease buildup around the pin joints

• Damage or wear to pins / bores

• Loose, damaged, or missing snap ring pin retainers

5.9 Swing Cylinders

Refer to "Hydraulic Cylinder Inspection Guidelines" for inspection procedure

• 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, bearings, and retainers

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

5.10 Swing Pins and Bearings

• Loose or broken pin flag and retainer bolts

• Irregular shaped pin bores

• Improper lubrication

• Broken or damaged grease lines or grease fittings

• Loose or damaged swing position sensor harness or connector

5.11 Lower Boom Area

• Hose connections for leaks

• Hoses for rubbing, damage, or wear

• Grease fittings for damage or leaks

• Boom lock

- for proper operation and damage to cable or locking mechanism

- for damaged or missing rest pads

• Loose or broken foot pin retainers and or irregular shaped pin bores

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

5.12 Boom Cylinder

Refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure

• 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 or snap ring retainers

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

5.13 Stick Cylinder

Refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure

• Leaks around hose connections

• Rubbing, damaged, or worn hoses

• Damaged or leaking grease lines

• Inspect boom to stick pin and stick to bucket cylinder pin

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

5.14 Extendable Stick

• Oil leaks indicated by dirt or oil buildup around the stick, stick extension channel and stick extension end plate

- Refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure

• Damaged or leaking grease lines

• Missing, damaged, or excessively worn wear plates

- Refer to OMM for procedure and maximum allowable wear

5.15 Backhoe Bucket Cylinder

- Refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure

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

• Oil leaks at hose connections

• Damage to cylinder rods

• Damaged or worn linkage pins or snap ring retainers

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

5.16 Backhoe Bucket Linkage

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

• Blown out pin joint lip seals indicated by dirt and grease buildup around the pin joints

• Loose, damaged, or missing cotters and snap ring pin retainers

• Irregular-shaped pin bores

• Loose, damaged, worn pin joints

5.17 Backhoe Bucket

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

Check wear plates for excessive wear

Check tips and adapters for

• Excessive wear on the bucket tip

- Replace tips that worn through on the bottom or cracked in the pocket area

• Damage to the bucket tip adapter

- Replace badly worn bottom straps that are worn into bottom cavity

• Damage or missing retainer pins

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

Performance Inspection

Hydraulic Performance Checks