- Off-Highway Truck/Tractor
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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.
Serial Number: | Inspector: | Temperature: | |||
Model: | Work Order: | Time: | |||
Engine S/N: | SMU: | Date: | |||
Manufacture: | Unit Location: | ||||
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 Off-Highway Truck 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.
- Click format to print.
- Save the document as an HTML format.
- Open the document with Microsoft Word.
1.0 Prepare Machine Inspection
Refer to "1.0 Inspection Preparation" section in "Inspection Reference" for more information for performing machine inspection preparation.
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 | |||
1.5 | Observe engine exhaust colors | |||
1.6 | Listen for unusual noises (hydraulic pumps, engine, transmission, and axles) |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
2.0 Lower-Level Inspection
Refer to "2.0 Lower-Level Inspection" section in "Inspection Reference" for more information for performing lower-level inspection.
Sl.No. | Status(1) | Description | Comments |
2.1 | Tires and rims | ||
2.2 | Front Wheels and Brakes | ||
2.3 | Rear Final Drives, Brakes, and Wheel Spindles | ||
2.4 | Differential Housing | ||
2.5 | Drive Shaft | ||
2.6 | Transmission and Transfer Gears | ||
2.7 | Rear Axle Housing Support | ||
2.8 | Hoist Control Valve | ||
2.9 | Rear Engine/Torque Converter Mounts | ||
2.10 | Brake Accumulator | ||
2.11 | Oil Coolers and Lines | ||
2.12 | Steering Cylinders and Steering Linkage | ||
2.13 | Engine Damper, Front Engine Trunnion Mounts, and Support Mounts | ||
2.14 | Secondary Steering/Brake Release Pump | ||
2.15 | Engine Oil Pan | ||
2.16 | Machine Frame |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
3.0 Middle-Level Inspection
Refer to "3.0 Middle-Level Inspections:" section in "Inspection Reference" for more information for performing middle-level inspection.
Sl.No. | Status(1) | Description | Comments |
3.1 | Mud Flaps | ||
3.2 | Front Suspension Cylinders | ||
3.3 | Fuel Lines, Fuel Pump, and Fuel Filter Base | ||
3.4 | Exhaust Manifold | ||
3.5 | Turbocharger | ||
3.6 | Brake Hydraulic Lines and Components | ||
3.7 | Steering Valves | ||
3.8 | Hydraulic Tank | ||
3.9 | Fuel Tank | ||
3.10 | Rear Suspension Cylinder | ||
3.11 | Ground Level Electrical Components | ||
3.12 | Work Lights | ||
3.13 | Radiator, Aftercooler, and Condenser | ||
3.14 | Cylinder Head and Valve Cover | ||
3.15 | Water Pump |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
4.0 Upper-Level Inspection
Refer to "4.0 Upper-Level Inspections:" section in "Inspection Reference" for more information for performing upper-level inspection.
Sl.No. | Status(1) | Description | Comments |
4.1 | Steps and Handrails | ||
4.2 | Hood and Platform | ||
4.3 | Precleaner and Air Cleaner | ||
4.4 | Pulleys, Belts, Compressor Clutch, and Alternator | ||
4.5 | Cooling Fan, Fan Guard and Shroud | ||
4.6 | Steering Tank | ||
4.7 | Cab Exterior | ||
4.8 | Cab Interior | ||
4.9 | Cab Mounts | ||
4.10 | Upper and Lower Radiator Lines, Air Inlet Lines, and Aftercooler Lines | ||
4.11 | Radiator Cap | ||
4.12 | Hydraulic Pump Compartment | ||
4.13 | Auto-Lube Pump, Tank, and Injectors | ||
4.14 | Rear Brake Lines and Components |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
5.0 Implement/Attachment Inspection
Refer to "5.0 Implement/Attachment Inspections:" section in "Inspection Reference" for more information for performing implement/attachment inspection.
Sl.No. | Status(1) | Description | Comments |
5.1 | Hoist cylinders | ||
5.2 | Truck body | ||
Body Liner | |||
Canopy | |||
Heated Body Exhaust Ports | |||
Rock Ejectors | |||
Rocker Shoes, Rest Pads & Shims | |||
Frame Rest Pads & Shims | |||
Body Position Switch |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
6.0 Site Conditions
Sl.No. | Status(1) | Description | Comments | |
6.1 | Ambient Temperature | |||
NORMAL: |
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MONITOR: |
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ACTION: Above |
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6.2 | Altitude | |||
NORMAL: |
||||
MONITOR: |
||||
ACTION: Above |
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6.3 | Haul Road Grade | |||
NORMAL: Flat | ||||
MONITOR: Mild | ||||
ACTION: Steep | ||||
6.4 | Haul Road Condition | |||
NORMAL: Positive Banking, Gradual Turns, Good Erosion Control | ||||
ACTION: Negative Banking, Sharp Turns, Poor Erosion Control | ||||
6.5 | Humidity | |||
NORMAL: Below 25% | ||||
MONITOR: 25 to 60% | ||||
ACTION: Above 60% | ||||
6.6 | Air Quality | |||
NORMAL: No Dust | ||||
MONITOR: Light Dust | ||||
ACTION: Heavy Dust | ||||
6.7 | Underfoot Condition | |||
NORMAL: Dry Flat Surface | ||||
MONITOR: Moderate Grades, Mixture of Muddy / Dry Surfaces | ||||
ACTION: Steep Grades, Muddy, Snow, Ice | ||||
6.8 | Machine Utilization | |||
NORMAL: 0 to 10 Hours | ||||
ACTION: Above 10 hours | ||||
6.9 | Equipment Role | |||
NORMAL: Utility | ||||
MONITOR: Support | ||||
ACTION: Production | ||||
6.10 | Working Material | |||
NORMAL: Uncompacted, Low Abrasion | ||||
MONITOR: Moderately Compacted, Moderate Abrasion | ||||
ACTION: High Abrasion, Compacted, Dense | ||||
6.11 | Maintenance Practices | |||
NORMAL: Excellent | ||||
MONITOR: Good | ||||
ACTION: Poor | ||||
6.12 | Primary Industries |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
Inspection Benefits:
- Minimizes downtime through scheduled maintenance
- Locates potential problems
- Finds overlooked problems
- Enables scheduled maintenance and repairs
- Lowers owning and operating costs
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
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
1.3 Perform safety/preparatory inspection
- 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.
1.4 Download machine fault codes
- Download machine fault codes using either of the following methods:
- Electronic Technician (ET)
- VIMS Advisor Monitoring System
1.5 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
1.6 Listen for unusual noises (Hydraulic Pumps, Engine, Transmission, and Axles)
- 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
- Excessive noise coming from the 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
2.0 Lower-Level Inspection
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 Differential Housing
- Check differential housing for leaks in the following areas:
- Sealing surface between the differential housing and the transmission housing
- Sealing surface between the differential housing and the wheel spindles
- Oil leakage around the drain and fill plugs
- If equipped, check the magnetic plug for metal particles.
- Check the following for loose or damaged axle housing joints, bolts, pins, retainers:
- Lateral control arm
- Transmission housing & axle housing support
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 seal
Grease leakage in these areas would indicate possible seal damage
2.6 Transmission & Transfer Gears
Check for:
- Leaks around hose connections
- Rubbing, damaged, or worn hoses
- Rubbing, damaged, or worn wiring harnesses or connectors
- Oil leakage around drain and fill plugs
- Oil or dirt buildup on the transmission and transfer gear housings. If visible, inspect:
- Sealing surfaces between axle housing and transmission housing
- Sealing surfaces between transmission housing and transfer gear
- Drive shaft yoke assembly seal
2.7 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
2.8 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
2.9 Rear Engine/Torque Converter 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 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 Secondary Steering/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
- Reference Special Instructions REHS1227 (Small OHT) or REHS0541 (Large OHT) for detailed instructions regarding frame maintenance, inspections, & repair.
3.0 Middle-Level Inspections:
3.1 Mud Flaps
Check for:
- Bent or damaged fenders
- Potential interference with tires
- Loose or missing mounting nuts, bolts, brackets, straps
3.2 Front Suspension Cylinders
Check for:
- Oil leaks indicated by dirt or oil buildup around the cylinder lip seal
- Nicked, scored, pitted cylinder boot
- 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:
- 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
- Cracks or other damage in the manifold housing
3.5 Turbocharger
Check for:
- Black soot around the areas where the turbocharger bolts to the exhaust manifold or to the exhaust pipe 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 located 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 belts for:
- Worn, cracked, or broken belts
- Proper belt tension
- Check for oil leaks around air condition compressor clutch
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 windshield 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 located 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
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 telescopic 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
Hoist Cylinder Tests
Status(1) | Description | Specification | Actual | Comments |
Lift Cycle Time for Hoist Cylinders |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
Cylinder Drift Test
Status(1) | Description | Specification | Actual | Comments |
Oil Temperature | ||||
Lift Cylinder Drift |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
Steering Turn Diameter Check
Status(1) | Description | Specification | Actual | Comments |
Full Steer Left | ||||
Full Steer Right |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
Brake Performance Checks
Status(1) | Description | Specification | Actual | Comments |
Service Brake Check (Test from OMM) | ||||
Secondary Brake Check (Test from OMM) | ||||
Parking Brake Check (Test from OMM) | ||||
Retarder Brake Check (Test from T&A) | ||||
Air System Warning Check (Test from T&A) |
(1) | N = Normal, M = Monitor, A = Action, Blank = Not Applicable |