795F M01 Walkaround Text

GLOBAL MANPOWER DEVELOPMENT
795F AC OFF-HIGHWAY TRUCK

WALKAROUND INSPECTION
MODULE 1 - TEXT REFERENCE
795F AC Off-Highway Truck

Module 1 - Walkaround Inspection
Text Reference
Field Development Use Only
© 2009 Caterpillar Inc.

Caterpillar: Confidential Yellow
795F AC Field Development- 07/09 -2- Module 1 - Walkaround
795F MAINTENANCE
ice
795F Serv
Procedure
WALKAROUND INSPECTION 2_1

INTRODUCTION
• Operation and Maintenance Before maintaining or operating the 795F truck, read the Operation and Maintenance
Manual Manual thoroughly for information on safety, maintenance, and operating
techniques.
• Safety precautions and warnings Safety Precautions and Warnings are provided in the manual and on the truck. Be
sure to identify and understand all symbols before starting the truck.
• Walk-around inspection The first step to perform when approaching the truck is to make a thorough walk-
around inspection. Look around and under the truck for loose or missing bolts, trash
build-up, and for coolant, fuel, or oil leaks. Look for indications of cracks. Pay close
attention to high stress areas.

3
4
5
2
1
1
3_1
• Right side of truck: Some of the items to inspect on the right side of the truck are:
1. Tire condition and inflation - tire condition and inflation pressure (1)
pressure
- front and rear wheel magnetic plugs and wheel nuts (2)
2. Front and rear wheel magnetic
plugs and wheel nuts - suspension cylinders (3)
3. Suspension cylinders - air tank moisture (if equipped) (4)
4. Air tank moisture (if equipped) - hydraulic tank oil levels (5)
5. Hydraulic tank oil levels - hydraulic oil filters (6)
6. Hydraulic oil filters

3
4 3
1
1
2
4_1
• Rear of truck: Some if the items to inspect at the rear of the truck are:
1. Rear suspension cylinders - rear suspension cylinders (1)
2. Truck body retaining locking - truck body retaining locking pins (2)
pins
- truck body retaining locking cables (3)
3. Truck body retaining locking
cables - lubrication bank (4)
4. Lubrication bank

6 5
4 3
2 2
1 1
5_1
• Left side of truck: Some of the items to inspect on the left side of the truck are:
1. Tire condition and inflation - tire condition and inflation pressure (1)
pressure
- front and rear wheel magnetic plugs and wheel nuts (2)
2. Front and rear wheel magnetic
plugs and wheel nuts - fuel level and moisture (3)
3. Fuel level and moisture - brake accumulators (4)
4. Brake accumulators - suspension cylinders (5)
5. Suspension cylinders - steering accumulators (6)
6. Steering accumulators - engine crankcase oil (bottom of oil pan)
7. Engine crankcase oil (bottom - grease level (7)
of oil pan)
8. Grease level

3
4 4
5 5
2 1
6_1
• Front of truck: Some of the items to inspect at the front of the truck are:
1. Batteries - batteries (1)
2. Remote switch panel - remote switch panel (2)
3. Radiator and coolant level - radiator and coolant level (3)
4. Air filters and precleaners - air filters and precleaners (4)
5. Dust valves - dust valves (5)
6. Inverter/rectifier filters
Some of the items to inspect on the platform are:
- engine compartment including belts and hoses

- windshield washer fluid level and A/C filter (left side of cab)
- inverter/rectifier filters (6)
• Inside cab Inside the cab check the seat belt, cab fresh air filter, secondary steering and the
brakes.

2
3
1 2
9 6
4
8
5
7_1
• Below truck: This illustration shows where some of the maintenance items are located from below
the truck:
1. Engine oil filters
2. Secondary fuel filters - engine oil filters (1)
3. Engine oil level - secondary fuel filters (2)
4. Hoist and brake cooling oil - engine oil level (3)
filter - hoist and brake cooling oil filter (4)
5. Brake filter - brake filter (5)
6. Fuel tank - fuel tank (6)
7. Final drive lube filters - final drive lube filters (7)
8. Hydraulic oil tank - hydraulic oil tank (8)
9. Hydraulic oil filters - hydraulic oil filters (9)

1 1
8_1
1
1
2 2 8_2
• Rear of truck: If the 795F truck body must be raised for servicing, ensure the truck body retaining
cables (1) on both sides of the truck are connected to the rear axle with the truck
1. Truck body retaining cables body retaining pins (2).
2. Truck body retaining pins
Stow the pins after removal as shown in the bottom illustration.
NOTE: Always read and follow the directions in the Operation and Maintenance
Manual (OMM) for the truck that is being serviced.

3
9_1
2 1
9_2
• Front wheel hubs: New on the “F” Series truck is the oil level sight glass that is installed on the front
wheel hubs. The oil level is checked through a sight glass (1) that is located in the
1. Sight glass center of the wheel housing. The oil should be level with the bottom of the fill plug
2. Magnetic fill plug hole. If necessary, remove the magnetic fill plug (2) in the center of the front wheel
3. Magnetic drain plug bearing housing to check the fluid level. Also, this plug is used to fill the front wheel
bearing housing.
4. Schrader valve
The oil is drained by removing the magnetic drain plug (3). When draining the oil
from the front wheel bearing housing, rotate the wheel so the drain and fill plug is at
the bottom. Inspect the plug periodically for metal particles. If any metal particles
are found, remove the wheel cover and inspect the bearings for wear.
Check the tire inflation pressure with the Schrader valve (4). Operating the truck with
the wrong tire inflation pressure can cause heat build-up in the tire and accelerate
tire wear.
NOTE: Care must be taken to ensure that fluids are contained while performing
any inspection, maintenance, testing, adjusting and repair of the machine.
Be prepared to collect the fluid in suitable containers before opening any
compartment or disassembling any component containing fluids. Refer to the
“Tools and Shop Products Guide” (Form NENG2500) for tools and supplies
suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids
according to local regulations and mandates.

10_1
• Front suspension cylinder (arrow) Check the right front suspension cylinder (arrow) for leaks or structural damage.
Check the charge condition of the front suspension cylinders when the truck is empty
and on level ground. Measure the charge height of the suspension cylinders and
compare the dimension with the dimension that was recorded the last time the
cylinders were charged. Recharge the cylinders with oil and nitrogen if necessary.
Inspect the condition of the front wheel bearing axle housing breather (not visible).
The breather prevents pressure from building up in the axle housing. Pressure in
the axle housing may cause brake cooling oil to leak through the Duo-Cone seals in
the wheel brake assemblies.
NOTE: For more detailed information on servicing the suspension system, refer
to the Special Instruction “Suspension Cylinder Servicing” (Form SEHS9411).

1
3
11_1
• Right side of engine: Check the engine oil filters (1), the secondary fuel filters (2), and the tertiary fuel
filter (3) for damage or leakage. The filter groups are located on the right side of the
1. Engine oil filters engine near the right front tire. The three fuel filters are located on one fuel filter
2. Secondary fuel filters base. The secondary fuel filters are in parallel and the tertiary filter is in series with
3. Tertiary fuel filter the secondary filters. Also, installed in the base are the filtered and unfiltered fuel
pressure sensors.

5
1
8 7
2
6
10
3 12
4
9 11
13 14
12_1
• Right side of machine: The three-section hydraulic tank includes the brake activation section (1), the hoist
and brake cooling section (2), and the steering/fan section (3).
1. Brake activation section
2. Hoist and brake cooling Check the hoist and brake oil cooling tank breather (not visible) and the steering
section tank breather (4) for proper operation. Ensure the hoist and brake oil tank section
3. Steering and fan section filler cap (5) and steering tank section filler cap (6) are properly tightened. To fill the
4. Steering tank breather hoist and brake oil cooling tank, remove the brake oil tank section filler cap and fill
5. Hoist and brake oil tank the brake section, which will overflow the brake section and fill the hoist and brake
section filler cap oil cooling tank section.
6. Steering tank section filler
cap The tank sight glasses are:
7. Brake activation oil level
8. Hoist oil level with body - brake activation oil level (7)
DOWN - hoist oil level with the body DOWN (8)
9. Hoist oil level with body UP - hoist oil level with the body UP (9)
10. Steering oil level with engine - steering oil level with the engine OFF and the accumulators purged (10)
OFF and accumulators purged - steering oil level with the engine RUNNING (11)
11. Steering oil level with engine
RUNNING The lower sight gauge can be used to fill the hydraulic tank when the hoist cylinders
12. Steering and fan oil cooler are in the RAISED position. When the hoist cylinders are lowered, the hoist oil level
13. Steering and fan return filter will increase. After the hoist cylinders are lowered, check the hydraulic tank oil level
14. Case drain oil filters with the upper sight gauge.

When filling the hydraulic tank after an oil change, fill the tank with oil to the FULL
COLD mark on the sight gauge. Turn on the engine shutdown switch so the engine
will not start. Crank the engine for approximately 15 seconds. The oil level will
decrease as oil fills the hydraulic system. Add more oil to the tank to raise the oil
level to the FULL COLD mark. Crank the engine for an additional 15 seconds.
Repeat this step as required until the oil level stabilizes at the FULL COLD mark.
Turn off the engine shutdown switch and start the engine. Warm the hydraulic oil.
Add more oil to the tank as required to raise the oil level to the FULL WARM mark.
Check the steering and fan oil cooler (12) and steering and fan return filter (13) for
damage or leakage.
There are two case drain oil filters (14) attached to the front of the tank. Check the
engine fan pump and motor case drain oil filter (upper filter) and the steering pump
and drive system cooling fan motor case drain oil filter (lower) for damage or leaks.

2 1
3
3
14_1
14_2
• Inside frame rail right side: Check for leaks at each of the hoist system high pressure screens (1) and the brake
cooling screen (2) which are located on the upper right side frame. Also, check the
1. High pressure screens hoses and fittings for damage or leaks and check the condition of the hoist screen
2. Brake cooling screen bypass switches (3).
3. Bypass switches
Check for leaks and/or damage to the parking brake release pump (4).
4. Parking brake release pump
Access the screens and the parking brake release pump with the body raised and
the truck body retaining cables properly installed.

3 5
15_1
• Rear wheels: The rear axles are equipped with double reduction planetary-type final drives. The
final drive oil level can be checked using the sight glasses (1).
1. Sight glasses
2. Final drive oil drain plug The final drive oil drain plug (2) is used to drain the final drive oil. Position the
3. Magnetic plug magnetic plug (3) in a horizontal line with the center of the axle and remove the plug
to fill the final drive housing. The oil should be level with the bottom of the plug hole.
4. Outer Schrader valve
Allow enough time for the oil to settle in all of the compartments. This can be as
5. Inner Schrader valve much as 20 minutes during cold temperatures.
The magnetic inspection plugs should be removed weekly from the final drives and
checked for metal particles. For some conditions, checking the magnetic plugs is the
only way to identify a problem.
The right and left rear wheel groups are equipped with two Schrader valves. The
outer Schrader valve (4) is used to inflate the outside tire and the inner Schrader
valve (5) is used to inflate the inside tire.

3
4
1 1
2
16_1
• Rear of machine: Check the rear suspension cylinders (1) for leaks or structural damage. Check the
charge condition of the rear suspension cylinders when the truck is empty and on
1. Rear suspension cylinders level ground. Measure the charge height of the suspension cylinders and compare
2. WAVS camera the dimension with the dimension that was recorded the last time the cylinders were
3. Backup alarm charged. Recharge the cylinders with oil and nitrogen if necessary.
4. Lubrication bank
Check each suspension cylinder for nitrogen leakage. It is difficult to detect a nitrogen
5. Axle cover leak. A solution that consists of soap and of water can be used to detect leaks. Make
sure that there is no leakage around the valve cores and around the valve bodies.
Make sure that the valve caps are in place.
If the rear suspension cylinders must be recharged, they must first be drained of all
nitrogen and oil.
Inspect the condition of the lens cover for the Work Area Visual System (WAVS)
camera (2). The camera is used by the operator for visibility at the rear of the truck.
Also, check the operation of the backup alarm (3).
The second of three lubrication bank (4) for the automatic lubrication system is
mounted above the differential housing.
The axle cover (5) can be removed to access the drive train wheel motors.

2
3
17_1
1
17_2
• Rear axle lubrication components: The final drive lube oil filters (1), the final drive lube motor (2), and the final drive lube
pumps (3) are located at the rear of the truck.
1. Final drive lube oil filters
2. Final drive lube motor Check the filters and pumps for damage and leaks.
3. Final drive pumps

1
3
18_1
• Left inner frame rail: The hoist and brake cooling oil filter (1) and the brake oil filter (2) are located on the
left side of the inner frame next to the drive system cooling duct (3). Check the filters
1. Hoist and brake cooling oil for damage and leaks.
filter
2. Brake oil filter
3. Drive system cooling duct

19_1
3 3
4
19_2
• Left side of truck: The upper illustration shows the fuel tank from the exterior of the truck. The fuel
tank (1) is located on the left side of the truck. Also shown is the fast fill
1. Fuel tank connector (2).
2. Fast fill connector
3. Primary fuel/water separators The lower illustration shows the primary fuel/water separators (3), which are located
on the inboard side of the fuel tank. Installed in the rear fuel/water separator is the
4. Water in fuel sensor
water in fuel sensor (4).

1 2
3 3
20_1
20_2
• Left side in front of fuel tank: The top illustration shows the location of the parking brake accumulator (1) and the
service brake accumulator (2). Check the accumulators for damage or leakage. The
1. Parking brake accumulator accumulators have a pressure tap (3) for checking accumulator pressure.
2. Service brake accumulator
3. Accumulator pressure tap The lower illustration shows the location of the fuel tank breather (4).
4. Fuel tank breather

3 2
21_1
• Left side of engine: The C175-16 Engine is equipped with two water-to-oil coolers (1) located on the left
side of the truck. The coolers are behind the left front tire. Check the condition of the
1. Oil coolers engine oil using the S•O•S tap (2). Check the engine oil pan (3) for damage or
2. S•O•S tap leakage.
3. Engine oil pan
The level of the engine oil can be view through the sight glass (4) in the oil pan. A low
4. Sight glass
engine oil warning switch located on the oil pan will send a signal to the Engine ECM,
which will log a warning whenever the oil level is too low. A second oil level warning
switch with illuminate the lamp on the fast fill center when the oil level is too low.

22_1
• Behind left front tire: Check the left front strut cylinder (1) for leaks or structural damage. Check the
charge condition of the front suspension cylinders when the truck is empty and on
1. Left front strut cylinder level ground. Measure the charge height of the suspension cylinders and compare
2. Steering accumulators the dimension with the dimension that was recorded the last time the cylinders were
charged. Recharge the cylinders with oil and nitrogen if necessary.
The “F” Series pilot trucks are equipped with three steering accumulators (2). The
accumulator are now equipped with a piston type replacing the bladder type that
was previously used. The new accumulators are nitrogen charged to approximately
6550 ± 331 kPa (950 ± 48 psi) at 21º C (70° F).

23_1
8 9 10 12 11 13
14
3 4 5 6 7
23_2
• Left side behind front bumper: Check the grease tank for damage and proper operation.
1. Micro switch Check the components on the top cover of the grease tank. The micro switch (1)
2. Caterpillar Fast Fill indicator installed on the top cover indicates that the grease level is at the FULL mark. The
panel level will be indicated on the Caterpillar Fast Fill indicator panel (2).
3. Hoist and brake oil tank The 795F truck may be equipped with the Caterpillar Fast Fill panel. The individual
section fast fill port fluid levels can be filled directly from the front of the truck. Also displayed on the
4. Steering oil tank section fast panel are the fluid level indicators.
fill port
5. Engine coolant fast fill port The fast fill ports and indicators are:
6. Engine oil fast fill port - hoist and brake oil tank section fast fill port (3)
7. Fuel tank fast fill port - steering oil tank section fast fill port (4)
8. Cold hoist oil full indicator - engine coolant fast fill port (5)
9. Hot hoist oil full indicator - engine oil fast fill port (6)
10. Engine oil full indicator - fuel tank fast fill port (7)
11. Engine coolant full indicator - cold hoist oil full indicator (8)
12. Steering oil tank full indicator - hot hoist oil full indicator (9)
13. Grease tank full indicator - engine oil full indicator (10)
14. Indicator light test switch - engine coolant full indicator (11)
- steering oil tank full indicator (12)
- grease tank full indicator (13)
- indicator light test switch (14)

24_1
• Front bumper The 795F truck with an electric start engine is equipped with dual sets of two 12 volt
batteries as shown in this illustration. The batteries are connected in series to supply
24 volts. Each set of 24 volts will be connected in parallel for additional current for
engine starting.
The 795F truck with an air start engine will have two 12 volt batteries connected in
series to supply 24 volts to the machine and engine systems.
NOTE: The 795F Pilot Trucks will not be equipped with an air start system.

25_1
3 4 5
2
6
9 10 8 7
25_2
• Right front bumper: On the right side of the front bumper is a switch panel for the truck control. The upper
illustration shows the control with the glass cover down and the blue light (1) on the
1. Blue light housing. The blue light will be illuminated whenever an active diagnostic code or an
2. Battery disconnect switch active event (Warning Level 2 or higher) from any of the ECMs on the truck is
3. VIMS payload application recognized by the VIMS module.
service connector
The lower illustration shows the following components on the remote switch panel:
4. Drive system lockout switch
5. Drive system lockout lamp - battery disconnect switch (2)
6. Starter lockout lamp - VIMS payload application service connector (3)
7. Starter lockout switch - drive system lockout switch (4)
8. Engine shutdown switch - drive system lockout lamp (5)
9. Engine work lamp switch - starter lockout lamp (6)
10. Ladder lamp switch - starter lockout switch (7)
- engine shutdown switch (8)
- engine work lamp switch (9)
- ladder lamp switch (10)
The engine shutdown switch is used to stop the engine from ground level. To shut
down the engine, raise the guard and move the toggle switch upward (OFF position).
When the engine has shut down, lower the guard. Lowering the guard will move the
toggle switch to the engine ON position.

The battery disconnect switch in the OFF position deactivates power to the truck.
The drive system lockout initiates NEUTRAL through the drive system control
allowing the technician to service the machine with a running engine. When the
drive system lockout switch is ON, the parking brake is ON and the ground speed is
zero, the indicator will be ON solid and the machine will be locked out. The indicator
will flash when the machine lockout switch is activated but either the parking brake is
OFF or the ground speed indication is not zero.
The starter lockout switch disconnects battery power to the starter relays on the
electric start engine or the air start relay on the air start engine. When the starter
lockout switch is ON and the ground speed is zero, the indicator will be ON solid and
the starter will be disabled. The indicator will flash when the starter lockout switch is
activated but the ground speed indication is not zero.

5 1
2
3
6
27_1 27_2
27_3 27_4
• Right front bumper: The powered access stairway can be raised and lowered using the stairway
switch (1) located next to the remote switch panel.
1. Stairway switch
2. Stairway motor The stairway switch activates the stairway motor (2), which drives the stairway
3. Stairway pump pump (3). The stairway pump provides oil to the cylinder (4), which moves the
stairway up or down.
4. Cylinder
5. Stair circuit breaker Also located next to the remote switch panel is the powered access stairway circuit
6. Auxiliary start receptacle breaker (5) and the auxiliary start receptacle (6).

3 1
4
2 28_1
• Front of truck: While climbing the diagonal ladder, make a thorough inspection of the radiator (1).
Be sure that no debris or dirt is trapped in the cores.
1. Radiator
2. Dust valves Check the dust valves (2) for plugging. If necessary, remove the cover for additional
3. Filter housings cleaning. The dust valve is OPEN when the engine is OFF and closes when the
engine is running. The dust valve must be flexible and closed when the engine
4. WAVS camera
is running or the precleaner will not function properly and the air filters will have a
shortened life. Replace the dust valve if the rubber is not flexible.
Two filter elements are installed in the filter housings (3). The large element is the
primary element and the small element is the secondary element.
Air intake system tips:
- The primary element can be cleaned a maximum of six times.

- Never clean the secondary element for reuse. Always replace the
secondary element.
- Air filter restriction causes black exhaust smoke, high exhaust temperatures,
and low power.
The Advisor Panel will also provide the operator with an air filter restriction warning/
derate depending on the degree of air filter restriction.
During the walk around, check/clean the camera (4) which monitors the view in front
of the truck.
2
1
29_1
• Top of platform: The cooling system on the 795F truck is a one coolant system. The separate circuit
aftercooler has been replaced with an Air-To-Air Aftercooler (ATAAC).
1. Sight gauge
2. Fill cap The coolant level for the radiator is checked with a sight gauge (1). The cooling
system is protected by a relief valve (not shown). If a cooling system overheats or if
coolant is leaking from a relief valve, clean or replace the relief valve.
The coolant shunt tank is equipped with a liquid level switch (not shown). This switch
reports to the truck Service Center.
The “F” Series truck will be filled with Extended Life Coolant (ELC) at the factory.
If ELC is maintained in the radiator, it is not necessary to use a supplemental
coolant additive. If more than 10% of conventional coolant is mixed with the ELC, a
supplemental coolant additive is required. Remove the fill cap (2) to add coolant.
NOTE: Never use water alone. All water is corrosive at engine operating
temperatures without coolant additives. Also, water alone has none of the
lubrication properties which are required for water pump seals.

30_1
• Inverter screens (arrows) Check the inverter screens (arrows) and service as necessary. Check for loose or
missing bolts on the inverter covers.

31_1
• Engine compartment Check the engine compartment for debris and check the belts and hoses for
damage.

2
1
32_1
• Left side of cab: The windshield washer reservoir (1) is located on the left side of the cab. Keep the
reservoir full of windshield washer fluid. The air conditioner filter (2) is also located
1. Windshield washer reservoir on the left side of the cab. Clean or replace the filter element when a reduction of air
2. Air conditioner filter circulation in the cab is noticed.

33_1
• Cab fresh air filter (arrow) Some of the 10 Hour or Daily checks performed in the operator’s compartment are:
- Brakes: Check operation

- Indicators and gauges: Test operation
- Seat belt: Inspect
- Back-up alarm: Test operation
- Secondary steering: Test operation
The brakes are checked by engaging one of the brake systems and placing the shift
lever in FIRST FORWARD. Accelerate the engine until the truck moves. The truck
must not move below 1300 rpm. This procedure should be repeated for the parking,
secondary, and service brake systems.
The cab fresh air filter (arrow) is located behind the seat. Clean or replace the cab
fresh air filter when necessary.
INSTRUCTOR NOTE: Refer to the Operation and Maintenance Manual for

more information on the remaining tests performed in the cab.

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GLOBAL MANPOWER DEVELOPMENT

795F AC OFF-HIGHWAY TRUCK

795F AC Off-Highway Truck

Field Development Use Only

© 2009 Caterpillar Inc.

WALKAROUND INSPECTION 2_1

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

- engine compartment including belts and hoses

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

Air intake system tips:

- The primary element can be cleaned a maximum of six times.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

© 2009 Caterpillar Inc.

- Brakes: Check operation

INSTRUCTOR NOTE: Refer to the Operation and Maintenance Manual for

© 2009 Caterpillar Inc.

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