Technical Analysis 1 (TA1) Visual Inspection for 795F AC Off-Highway Trucks {0372, 1000, 7000, 753S, 7565} Caterpillar

Off Highway Truck

795FAC (S/N: ERM1-UP)

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 section "2.0 Lower-Level Inspections" 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 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

• Park the machine in a level place clear free of personnel and obstacles

• Put the transmission in the “Park” position

• Apply the parking brake

• Lower the truck body

• Turn the engine start switch to OFF and remove the key

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

• Walk around the machine and inspect underneath the machine for visible signs of fluid leaks.

• Check the engine oil, hoist/converter/brake oil, transmission oil, steering oil, and coolant levels. If necessary, add oil or coolant to reach minimum level for each system.

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 Observe engine exhaust colors

Start the machine and watch exhaust colors

• White Smoke after initial startup could indicate coolant in engine cylinder

• Blue Smoke during startup indicates oil in engine cylinder

• Black Smoke during startup may indicate plugged air filter

• Continuous Black Smoke indicated improper air/fuel mixture

• Continuous Gray Smoke indicate fuel timing problem

1.6 Listen for unusual noises (Hydraulic Pumps, Engine, Transmission, and Axles)

Excessive noise coming from Hydraulic Pump could indicate:

• Pump cavitation

• Loose or failed bearing

Excessive noise coming from engine compartment could indicate:

• Fuel injector knocks

• Engine bearing damage

• Valve train damage

Excessive noise coming from transmission when traveling could indicate:

• Pump cavitation

• Loose or failed bearing

• Clutch disc or gear damage

Excessive noise coming from rear differential/final drives and drive train when traveling could indicate:

• Gear damage

• Loose or failed bearing

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

- Tread worn down to the built-in wear indicators

- Tire cords or exposed fabric

- Uneven tread wear

2.2 Front Wheels and Brakes

Check the following for leaks:

• Sealing surface between the wheel cover and the wheel hub

• Oil leakage around the drain and fill plugs

• Duo-cone seal located between the wheel hub and the brake pack housing

• Duo-cone seal located between the brake pack housing and the axle housing

• Sealing surfaces between the various brake pack housing components

• Brake cooling oil & hydraulic oil lines & connectors

If equipped, check the magnetic plug for metal particles.

2.3 Rear Final Drives, Brakes & Wheel Spindles

Check the following areas for leaks:

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

• Oil leakage around the drain and fill plugs

• Sealing surface between the final drive housing and the rear wheel housing

• Duo-cone seal located between the rear wheel housing and wheel spindle

• Duo-cone seal located between the brake pack housing and the rear wheel housing

• Sealing surfaces between the various brake pack housing components

• Brake cooling oil & hydraulic oil lines & connectors

If equipped, check the magnetic plug for metal particles.

2.4 Traction Motor Housing

Check for:

• Rubbing, damaged, or worn wiring harnesses or connectors

• Loose or missing retainer bolts or pins

2.5 Drive Shaft

Check for :

• Loose or missing U-joint retainer bolts

• Worn or loose U-joints or drive shaft spline

- Use a pry bar to pry between yoke and U-joint or between the frame and drive shaft spline to check for movement. Movement in these areas would indicate excessive wear.

• Grease leaking from U-joint seals or from drive shaft spline

- Grease leakage in these areas would indicate possible seal damage.

2.6 Rear Axle Housing Support

Check for :

• Loose or damaged spherical bearing retainer bolts

• Loose or damaged retainer block mounting bolts

• Irregular shape pin bores or excessive pin wear

• Damaged grease lines or fittings

2.7 Hoist Control Valve

Check for:

• Leaks around connection points for hose and control valve components

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses and connectors

2.8 Gear Motor (Final Drive Lubrication)

Check for:

• Leaks around connection points for hoses

2.9 Rear Engine/Generator Mounts

Check for:

• Structural damage to support brackets & engine supports

• Structural damage or weld cracks on frame supports

• Loose or damaged support mounting bolts

2.10 Brake Accumulator

Check for:

• Leaks around connection points for hoses

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses and connectors

2.11 Oil Coolers & Lines

Check for:

• Leaks around hose connections

• Rubbing, cracked, and damaged hoses

• Loose connections

• Improperly secured hoses

2.12 Steering Cylinders and Steering Linkages

• Check steering cylinder for: (Refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure)

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

• Damage to cylinder rods

• Oil leaks at hose connections

Check steering linkages for:

Oil leaks at hose connections

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

• Damage to cylinder rods

• Oil leaks at hose connections

2.13 Engine Damper, Front Engine Trunnion, Support, Trunnion Mounts, Support Mounts

Check:

• Fluid filled engine damper for fluid leaks

• Trunnion & Support Mounts for:

- Structural damage

- Loose or damaged bolts

- Worn or damaged rubber pads

2.14 Brake Release Pump

Check for:

• Oil leaks at pump connections

• Rubbing, damaged, or worn hoses or tubes

• Rubbing, damaged, or worn wiring harnesses or connectors

• Loose wiring connections

2.15 Engine Oil Pan

Check for oil accumulation 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 valve, dipstick tube, turbo Lube return.

2.16 Machine Frame

Check for:

• Damage to frame

• Structural cracks

• Cracked welds

Refer to Special Instruction, REHS1227, "Procedures for the Inspections, Repairs, and Component Replacements on the Frames and Support Assembly of Certain Off-Highway Trucks" or Special Instruction, REHS0541, "Procedures for the Inspection, Repair, and Component Replacement on the Frames of Certain Off-Highway Trucks/Tractors" for detailed instructions regarding frame maintenance, inspections, & repair.

2.17 Air Starter (if Equipped)

Check for:

• Loose connections

• Excessive moisture discharge

2.18 Batteries

Check for:

• Corrosion on terminals and cables

• Loose connections

3.0 Middle-Level Inspections:

3.1 Mud Flaps

Check for:

• Loose or missing mounting nuts, bolts, brackets, straps

• Bent or damaged fenders

- Potential interference with tires

3.2 Front Suspension Cylinders

Check for:

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

• Nicked, scored, pitted cylinder rods

• Loose or missing cylinder boot

• Structural damage or weld cracks

• Damaged or loose steering arm or cylinder cap bolts

• Damaged or loose suspension cylinder mounting bolts

• Improperly lubricated bearing cap

• Broken or damaged grease lines, grease fittings, or grease seals

• Rubbing, damaged, or worn wiring harnesses or connectors

• Cylinder charge height (Dimension “x”) Reference the OMM & T & A manual for measurement specifications.

3.3 Fuel Line, Pump & Filter Base

Check fuel priming pump, primary/secondary fuel filter bases, and fuel injection pump for:

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

• Loose connections

• Leaks

3.4 Exhaust Manifold

Check for:

• Cracks or other damage in the manifold housing

• 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

- Where the exhaust manifold bolts to the turbocharger turbine inlet

3.5 Turbocharger

Check for:

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

- Loose connections at the joints

- Loose or broken mounting bolts

• Oil leakage around the turbocharger oil line

• Dirt tracks which may indicate air inlet or boost air leaks due to loose or damaged hoses, clamps on:

- Air inlet tubes and compressor housing

- Turbo boost air lines

- Turbo wastegate and wastegate boost lines

3.6 Brake Hydraulic Lines & Components

Inspect the following components:

• Service Brake Valve

• Cab Brake Manifold

• Front Brake Slack Adjuster on the left hoist cylinder frame support

Check for:

• Leaks around hose connections

• Rubbing, damaged, or worn hoses

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

3.7 Steering Valves

Inspect the steering pressure control valve & steering disable valve for:

• Leaks around connection points for hose and control valve components

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses and connectors

3.8 Hydraulic Tank

Check:

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

• Tank caps 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

3.9 Fuel Tank

Check for:

• Leaks

• Structural damage to tank, welds

• Breather and fill cap

• Loose or damaged bolts

• Worn or damaged rubber mounts

3.10 Rear Suspension Cylinders

Check for:

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

• Nicked, scored, pitted cylinder rods

• Loose or missing cylinder boot

• Structural damage or weld cracks

• Broken or damaged grease lines or fittings

• Loose, damaged, or missing pin retaining bolts

• Irregular shaped pin bores

• Rubbing, damaged, or worn wiring harnesses or connectors

• Cylinder Charge Height (Dimension “x”) Reference the OMM & T & A manual for measurement specifications

3.11 Ground Level Electrical Components

Check the following for proper operation:

• Compartment covers, latches, hinges

• Battery disconnect switch

• Engine disconnect switch

• Auxiliary start (jump-start) receptacle

• Starter & alternator circuit breakers

• Machine lockout control & light

• Engine lockout control & light

• Machine access light switch

3.12 Work Lights

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

• Proper operation

• Cracked or broken lenses

• Damaged wiring harnesses

• Loose or damaged mounting brackets

3.13 Radiator, Aftercooler & AC Condenser

Check for:

• Plugged screens

• Plugged cores

• Damaged fins

Note: Inspect both sides of cores, when possible.

3.14 Cylinder Head and Valve Cover

Check for:

• Oil and dust buildup around the sealing surfaces of the valve covers or cylinder head gasket. Leakage in this area would indicate:

- Loose connection at the joint

- Damaged gasket or seal

3.15 Water Pump

Check Primary (& Auxiliary) Pump for:

• Coolant leaks around water pump mounting flange

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

4.0 Upper-Level Inspections:

4.1 Steps & Handrails

Ensure that steps and handrails are in place. Check for:

• Damaged, missing, or loose bolts

• Damage to steps or handrails

• Excessive dirt or debris

4.2 Hood & Platform

Check for:

• Debris or excessive dirt on service platform

• Loose or damaged bolted access covers

• Proper function of access panels, latches, hinges

• Loose or damaged platform mounts, bolts

4.3 Pre-cleaner and Air Cleaner

Check for:

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

• Loose or damaged hose clamps on air inlet tube

• Loose or damaged air cleaner covers, clamps

4.4 Pulleys, Belts, Compressor Clutch, and Alternator

Check for oil leaks around air condition compressor clutch

Check belts for:

• Worn, cracked, or broken belts

• Proper belt tension

4.5 Cooling Fan, Fan Guard, and Shroud

Check for:

• Loose, damaged, or missing bolts

• Loose or damaged wire fan guard

• Loose or damaged fan shroud

• Damaged, cracked, or missing engine fan blades

4.6 Steering Tank & Lines

Check for:

• Loose or damaged tank mounts & mounting bolts

• Leaks at tank assembly sealing surface gasket, nuts, bolts

• Cracks, leaks in oil level sight glass

• Leaks at hydraulic filter bases & line connections

Make sure that breather is clean and properly ventilating

• Check by depressing the pressure relief button on top of breather

4.7 Cab Exterior

Check for:

• Bent or damaged cab structure

• Cracked or broken glass

• Damaged or missing mirrors

• Worn or broken window wiper arm or wiper blade

4.8 Cab Interior

Check 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

4.9 Cab Mounts

Check for:

• Loose or damaged bolts

• Worn or damaged rubber mounts

4.10 Upper & Lower Radiator Lines, Air Inlet Lines, and Aftercooler Lines

Check for:

• Rubbing, cracked, or damaged hoses

• Loose, over-tightened, damaged hose clamps

4.11 Radiator Cap

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

4.12 Hydraulic Pump Compartment

Check for:

• Leaks around hose connection points

• Rubbing, damaged, or worn hoses

• Loose or damaged hose clamps on pump suction lines

• Rubbing, damaged, or worn wiring harnesses or connectors

4.13 Auto-Lube Pump, Tank, Injectors

Check for:

• Leaks around connection points for hoses

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses and connectors

4.14 Rear Brake Lines & Components

Inspect the following components:

• Parking Brake Valve

• TCS Control Valve

• Rear Brake Slack Adjuster

• Secondary Brake Pressure Switch

• Brake Diverter (Towing) Valve on the left hoist cylinder frame support

Check for:

• Leaks around hose connections

• Rubbing, damaged, or worn hoses

• Rubbing, damaged, or worn wiring harnesses or connectors

4.15 Inverter Cabinet

Check for:

• Dust built up around cabinet and screens

5.0 Implement/Attachment Inspections:

5.1 Hoist Cylinder Refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure

Check for:

• Oil leaks indicated by dirt or oil buildup around telescoping rod & cylinder lip seals

• Oil leaks at hose connections

• Damage to cylinder rods

• Damage or wear to truck body linkage pins & retainer plates

• Grease leaking from frame bearing retainer, cap

• Broken/damaged grease lines, fittings

5.2 Truck Body Inspection

Check for excessive wear, structural damage, or weld cracks on:

• Body liner

• Canopy

• Heated Body Exhaust Ports

• Rock Ejectors

Check for improper adjustment, excessive wear, or damage to:

• Rocker Shoes, Rest Pads & Shims

• Frame Rest Pads & Shims

• Body Position Switch

• Body Retaining Cables

Performance Inspection

Hydraulic Performance Checks

Hoist Cylinder Tests

Steering Performance Checks

Steering Turn Diameter Check

Brake Performance Checks