2022105103 Technical Analysis 1 (TAt) Visual Inspection for Off-Highway Trucks {0372, 0374, 1000, 7000, 7538, 7565) (MO067346-04) ‘SMCS - 0372, 0374, 1000, 7000, 7538, 7565 Off-Highway Truck/Tractor All losesa4os Introduction Inspections are the most basic form of condition monitoring. Inspections arg easy todo and surprisingly eflective at helping you spot equipment health issues. Proactive monitoring and analysis of equipment information wil allow Dealers to effectively intervene before problems occu Noto: Before adjusting product settings to comply with Isted baseline TAL values, eonsut SIS forthe latest specification values Serial Number Inspector: Temperature: ‘Model Work Order: Time: Engine SiN ‘smu: Date: Manufacture: Unit Location: Note: Review Machine & 8.0.8, History and check for Active Service Letters prior to inspection Status of the Machine ‘The status recommendation of your Off-Highway Truck ist Table 1 (ora, = Down Machine, M= Monts Arson Visual Inspection 1.0 Prepare Machine Inspection Refer to "1.0 Inspection Preparation’ section i “ispection Reference” for more formation for performing machine inspection preparation, SING, [Status Description ‘Comments 4 ‘Chock with customer for operator complaints 12 Prepare the machine for the inspection 13 Perform safety/preparatory inspection 14 Download machine fault codes 1 15 Observe engine exhaust colors: = 16 Listen for unusual noises (hydraulic pumps, engine, transmission, Table 2 2.0 Lower-Level Inspection 2.0 Lower-Level Inspection" ction in “Inspection Reference" for more information for performing lower-level inspection ‘SIN, [Status Description ‘Comments 2A Tires and rims 22 Front Wheols and Brakes 23 Rear Final Drives, Brakes, and Wheel Spindles 24 Differential Housing Drive Shaft Transmission and Transfer Gears: Rear Axle Housing Support Hoist Control Valve Roar Engine/Torque Converter Mounts Brake Accumulator Oil Coolers and Lines ‘Steering Gylinders and Steering Linkage Engine Damper, Front Engine Trunnion Mounts,214 ‘Secondary Steering/Brake Release Pump 2.48 Engine Oil Pan 246 Machine Frame Table 3 "We Nomal M'= Monto, = Aton, Blank = Not poate 3.0 Middle-Level Inspection Refer to "3.0 MiddleLevel Inspections" section in "inspection Reference” for more information for performing midleevel inspection, ‘SIN, [Status Description [Comments 34 Mud Flaps p 32 Front Suspension Cylindors 33 Fuel Lines, Fuel Pump, and Fuel Filter Base | 34 Exhaust Manifold i] 35 Turbocharger i 36 Brake Hydraulic Lines and Components 37 Stooring Valves f 38 Hydraulic Tank 39 Fuel Tank 3.40 Rear Suspension Cylinder ant Ground Level Electrical Components 3.42 Work Lights 3.43 Radiator, Atercooler and Condenser 344 ylindor Head and Valve Cover t 3.45 Water Pump Table 4 N= Nom, M = Mor, A Aton Blank = No Bt 4.0 Upper-Level Inspection Refer to "4.0 Upper-Level Inspections" section in “inspection Reference” foc more information for performing upperieve inapedton ‘SIN, [Status Description ‘Comments aa ‘Stops and Handrails 42 Hood and Platform 43 Procleaner and Air Cleaner 44 Pulleys, Belts, Compressor Clutch, and Alternator 45 Cooling Fan, Fan Guard and Shroud 46 ‘Steering Tank 47 Cab Exterior 48 Cab Interior 49 Cab Mounts 440 Upper and Lower Radiator Lines, Ar Inlet Lines, and Aftercooler Lines. ant Radiator Cap 442 Hydraulic Pump Compartment 433 ‘Auto-Lube Pump, Tank, and injectors aaa Rear Brake Lines and Components Table § 5.0 Implement/Attachment Inspection Refer to°5.0 Implement/Atichment inspections” secton in "Inspection Reference" for more information for performing mplemenvfattachment inspection.‘SIN, [Status Description [Comments 54 Hoist cylinders “Truck body Body Liner Canopy 52 Heated Body Exhaust Ports Rock Ejectors Rockor Shoos, Rest Pads & Shims Frame Rest Pads & Shims Body Position Switch Table 6 ‘SIN, [Status Description ‘Comments ‘Ambient Temperature et NORMAL: 18 to 32°C (0t0 90°F) MONITOR: 32 to 46 °C (90 to 118 °F) or ~18 to-29°C (010 20°F) [AGTION: Abovo 46° C (115° F) or Bolow ~29° ¢ (-20°F) Ade 7 NORWAY 0 to 124m Of 90 MONITOR 12403048 m (00 to 10000) ACTION: Above 304 m 0001) Hau Road Grade a NORWAL! Fat MONITOR: mia “2h —AeTION: Steep au Road Condon o NORWA Postve Baking, Gradual Tun, Gadd Erosion Cont! ACTION: Negntv Bating, Sharp Tus, Poor Exsion Gono! amity es ACTION: Above 60% NORWAL: No Dust es MONITOR: Light Dust ACTION: Heavy Dust deo! Condon o NORWAL: Bry Fat Surface MONITOR: Moderate Grades, Mure of Muddy Dry Surfaces ACTION: Seep Grades, Mud, Snow ce Machine Uiliznon 8a NORWALO 10 Hours ‘ACTION: Above 10 hours Eaupment Rol WORWAL Uy eo HONOR: Suppor ‘ACTION, Production 70 Working Matera NORMAL: Uncompacted, Low Abrasion MONITOR: Moderately Compacted, Moderate Abrasion‘ACTION: High Abrasion, Compacted, Dense Maintenance Practices NORMAL: Excellent ent MONITOR: Good ‘ACTION: Poor 612 Primary Industries Table 7 Inspection Reference Inspection Benefits: + Minimizes downtime trough scheduled maintenance + Locates potential problems «Finds overlooked problems + Enables scheduled maintenance and repairs + Lowers ouning and operating costs Guidelines Wiring Harness Inspection Guidelines Check for: + Tubes, hoses, and ing harnesses rubbing against ne anather Sharp comers Bot heads + Tubes, noses, and wing harnesses nol rope secured Missing cps andlor wire tes Pips not attached Hamess Connector Inspection Guidelines Chock for connectors: + Not propery secured in place + Rubbing against machine ame + Rubbing aganst sharp edges Implement Linkage Pin Inspection Guidelines Check tor: + Loose or broken lange mounting bolt + Elongated bolt hole in flange (hole is located behind pin retaining bolt) + Loose or missing pin retainer bots «+ Iregular shaped pin bores Hydraulic Cylinder Inspection Guidelines: Check for: ‘+ Ol leaks indicated by it or ci buldup around the cylinder lip seat+ Oilloaksathose connections + Damage to cylinder rods + Damage or wear to linkage pins (eer to “Pin Inspection Guidelines" fr inspection procedure) 1.0 Inspection Preparation 44 Check with customer for operator complaints 4.2 Prepare the machine forthe inspection + Park the machine ina level place clear fee of personnel and obstacles + Put the transmission inthe "Park position ‘opty the parking brake + Lower the truck body + Tur the engine star switch to OFF and remove the key 1.3 Perform safetypreparatory inspection + Make sure no one is underneath the machine, around the machine, or on the machine. Be sure that the areas ee of personnel + Walkaround he machine and inspect underneath the machine orWisbe ign of uid leaks + Check the engine ol, hoistconverterbrake ol transmission ol, steting ol and coolant levels. necessary, ad olor coolant o reach ‘minimum level for each system, 1.4 Download machine fault codes + Download machine faut codes using ether of the folowing methods: Electronic Technician (ET) VIMS Advisor Mentoring System 1.8 observ ngine exhaust colors + Stat the machine and observe exhaust odor: \Wihite smoke ater intial startup could indieate cool nthe aging cylinder Blue smoke during startup may indicate olin the engine cylinder Black smoke during startup may indate plugged arte - Continous black smoke could indicate Improper aire mture Continous gray smoke may indicate fel timing probe 1.6 Listen for unusual noises (Hydraulic Pumps, Engine, Transmission, and Axles) + Excessive noise coming from hydraulic pump could indicate either: Pump cavilation ‘loose or failed bearing ‘+ Excessive noise coming from engine compartment could indicate: Fuel injector knocks Engine bearing damage ave train damage ‘+ Excessive noise coming from the transmission when traveling could indicat: Pump cavitation = Loose or flied bearing~ Ciuc disc or guar damage + Excossve noise coming rom rer diferentlfinal dives and deve train when waving coud indicate oar damage Loose o falls bearing 2.0 Lower-Level Inspection 2: Tires and Rims Check for: + Proper infation + Cuts, cracks, splits, oF bruises in the tread or sidew ‘area, Bumps or bulges may inccate tre separation + Cracks, its ftom coresion, or other visible damage toms, + Safe tread depth = Tread worn down to the buitin wear indicators = Tre cord or exposed fabric - Uneven read wear 2.2 Front Wheels and Brakes + Check the following for leaks Sealing surface between the wheel cover and the whee hub i leakage around ihe dain and fil plugs _Duo-cone seal located between the whee! hub an the brake pack housing ‘Duo-cone seal located between the brake pack housing nd the ane housing Sealing surfaces between the various brake pack housing components Brake cooling ol & hydraulic ol lines & connectors + Ifequipped, check the magnetic plug for metal particles 2.3 Rear Final Drives, Brakes & Whee! Spindles + Check the following areas for leaks: ~ Sealing surface between the axle cover and the! final dive planet cari - Oi eskage around the drain and fi plugs, - Sealing surface between the inal rive hoUsiag nd the reac whee! Rowing - Duo-cone seat located between the rear wheel housing and itiee!spndie ‘Duo-cane seal located between the brake pack housing and the réarwbee housing Sealing surfaces between the various brake pack housing components Brake cooling ol & hydraulic ol ines & connectors + Ifequipped, check the magnetic plug for metal particles ‘+ Check sitferential housing fr leak inthe following areas: - Sealing surface between the ciferential housing and the transmission housing Sealing surface between te differential housing and the whee! spindles il feakage around the rain and fil plugs+ ITequipped, check the magnetic plug for metal particles + Check the following for loose or damaged axle housing ont, bots, pins, retainers Lateral contro arm = Transmission housing & axle housing support 2.5 Drive Shaft Check for: + Loose or missing Ujoint retainer bots + Worm or loose Ujeints or ve shat spine Use a pry bar to pry between yoke and Usoint or between the frame and drive shaft spline to check fr movement. Movement in these areas would Indicate excessive wear. + Grease leaking trom Uoint seals or fom stve shat spine sel Grease leakage in these areas would indicate possible seal damage 26 Transmission & Transfer Gears Chock for: + Leaks around hose connections Rubbing, damaged, or wom hoses + Rubbing, damaged, or woe wing harnesses or connectors + Oil eakage around drain and fl plugs + Oil or dit buildup on the transmission and transfer gear hovsings/ yb, inspect Sealing surfaces between axle housing and transmission housing Sealing surfaces between transmission housing and transfer gear Drive shaft yoke assembly sea 2.7 Reat Axle Housing Support Check for: + Loose or damaged spherical bearing retainer bolts + Loose or damaged retainer block mounting bolts + lregular shape pin bores or excessive pin wear + Damaged grease ines or itings 28 Hoist Controt Valve Check for: + Leaks around connection points fr hose ae antl valve components + Rubbing, damaged, or wom hoses + Rubbing, damaged, or wom wring harnesses and connectors 2.8 Rear EngineTorque Converter Mounts check for: + Siructural damage to support brackets 8 engine supports + Sructural damage or weld cracks on frame supports + Loose er damaged support mounting Bolts2:10 Brake Accumulator Check for: + Leaks around connection points for hoses + Rubbing, damaged, or wom hoses + Rubbing, damaged, or wom wiring harnesses and connectors 2.1 Oil Coolers & Lines Check for: + Leaks around hose connections + Rubbing, cracked, and damaged hoses + Loose Connections + Impropery secured hoses, 2.12 Steoring Cylinders and Steoring Linkages + Check steering eyinder for: (Refer to “Hydraule Cylinder Inspecton Guidelines for inspection procedure) Ol leaks inated by drt rot buldup around the cylinder ip seal Damage o cylinder rods Ol leaks at hose connections + Check steering inkages for: Ol oaks inccated by drt ro buldup around the cylinder ip sat Damage o oylnder rods Oi oaks at hose connections 2.13 Engine Damper, Front Engine Trunnion, Support, Teunnion Mounts; Support Mounts chee + Fluid filed engine damper fr fd leaks + Trunnion & Support Mounts fr: - Stuctural damage Loose or damaged bolts Won or damaged rubber pads 2.14 Secondary Steoring/Brake Release Pump check for: + Oil leaks at pump connections + Rubbing, damaged, or wor hoses of tubes + Rubbing, damaged, or wor wing harneste of connectors + Loose wiring connections 2.45 Engine oll Pan CCheck for oll accumulation on the bottom of the oll pan + Ifelis found on the pan, inspect the folowing: (check for ea round the oll pan mounting lange Check for leaks around the ol evel sensor, dain valve, dipstick tube, turbo lube return2.46 Machine Frame + Check fr: Damage to frame - Structural racks + Cracked welds + Reference Special Instructions REHS1227 (Small OHT) or REHSO541 (Large OHT) for detailed instructions regarding frame maintenance, inspections, 8 repair, 3.0 Middle-Level Inspections: 3.4 Mud Flaps check fr + Bent or damages fenders Potential interference with tes + Loose or missing mounting nuts, bolts, brackets, straps 3.2 Front Suspension Cylinders check for: + Ol leaks indicated by it or all buldup around the eyindar ip seat + Nicked, scored, pitted cylinder boot + Loose or missing cylinder boot + Structural damage or weld cracks + Damaged or loose steering a or eyinder cap bolts + Damaged or loose suspension cylinder mounting bots + Improperly lubricated beating cap + Broken or damaged grease lines, grease fitings, or grease eats + Rubbing, damaged, or wom wiring harnesses or connects + Gylnder charge height (Dimension "), Reference the OMW 8 T&A manual fr measurement specications. 33 Fuel Line, Pump & Filter Base Check uel priming pump, primarylsecondary fue fier bases, afd fue injection pump for: + Damaged, rubbing, oF wor fuel ines or hydrate ines, + Loose connections + Leaks 3.4 Exhaust Manifold Check for: + Black soot indicating a loose, broken, damaged eonnécon around the folowing Zealing surfaces: - Where the exhaust manifold bots tthe elnder head - Clamps and bales between manifold segments on ear cylinder head - Where the exhaust manifold bots othe turbocharger turbine inet + Cracks or other damage in the manifold housing 3.5 TurbochargorCheck for: + Black soot around the aress where the turbocharger bots tothe exhaust manifold or othe exhaust pipe woud indicate Loose connections atthe joints = Loose or broken mounting bots + Oil leakage around the turbocharge one ‘+ Dirt tracks which may indicate air inlet or boost air leaks due to loose or damaged hoses, clamps on - Aint tubes and compressor housing Turbo boost ai lnes Turbo wastegate and wastegate boost nes 5.6 Brake Hydraulic lines & Components + Inspect the folowing components: ~ Service Brake Vale Cab Brake Manta Front Brake Slack Adjuster located onthe let hoist elinder frame support + Check or: Leaks around hose connections Rubbing, damaged, or worn hoses Rubbing, damaged, or worn wreihamnessiconnecocs 3,7 Steering Val Inspect the steering pressure control valve & steering disable valve for: + Leaks around connestion points fr hose and contol valve components + Rubbing, damaged, orwom hoses + Rubbing, damaged, or wom wring harnesses and connectors 3.8 Hydraulic Tank Check: + Upper & lower mounts for loose mounting bolts and structiraleracks on frame moUnting brackets + Tank caps seats for damage + Breather for dit and debris buildup + Hycrouti 5 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 fil cap + Loose or damaged bots + Wom or damaged rubber mounts3:10 Rear Suspension Cylinders Check for: + Oil oaks indicated by dirt oro buildup around the eyindr lip seal + Nicked, scored, pied oyinder rods + Loose or missing eyinder boot + Sructura damage or wel cracks + Broken or damaged grease lines or fitings + Loose, damaged, or missing pin retaining bots regular shaped pin bores + Rubbing, damaged, or worn wring hamesses or connectors + Oyfnder Charge Height (Dimension Reference the OMM & T&A manual for measurement specications 11 Ground Level Electrical Components chock the folowing fo proper operation: + Compartment coves aches, hinges + Battery disconnect sch + Engine disconnect switch ‘Aunlar start ump stat receptacle + Starter & alternator ckcut breakers + Machine lockout cont! & ight + Engine lockout cont & ight + Machine access light eich 3:42 Work Lights Ccheck road lights, turn signals, hazard flashers, work lights, and other + Proper operation + Cracked or broken lenses + Damaged whing hamesses + Loose or damaged mounting brackets 3.13 Radiator, ftrcooler & AC Condenser + Check for Plugged screens, Plugged cores Damaged fins + Note: Inspect both sides of cores, when po 3.14 Gylindor Hoad and Valve Cover Check for: + Oil and dust buildup around the sealing sur ofthe valve covers of cylinder head gaske. Leakage inthis area would indicate: Loose connection atthe int Damaged gasket or seal3.45 Water Pump (check Primary (& Auxiliary) Pump for: + Coolant leaks around water pump mounting flange ‘+ Coolant leaks through the weep hole inthe water pump housing 4.0 Upper-Level Inspection: 44 Stops & Handrails Ensure that steps and handrail In place. Check for: + Damaged, missing, or loose bots + Damage to steps or handrais + Excessive dit or debris 4.2 Hood & Platform Chock for: + Debris or excessive dit on service platform + Loose or damaged bolted access covers + Proper function of access panels, latches, hinges + Loose or damaged platform mounts, bots check fr + Dirt andor debris in the air re-cleaner + Loose or damaged hose lamps on airinet tbe + Loose or damaged air cleaner covers, clamps 4.4 Pulleys, Bots, Compressor Clutch, and Alternator + Check bets fr: Worm, eracked, or broken belts - Proper bet tension + Check fore eaks around air eondiion compressor clutch 45 Cooling Fan, Fan Guard, and Shroud Check for: + Loose, damaged, or missing bots + Loose or damaged wie fan guard + Loose or damaged fan shroud + Damaged, cracked, or missing engine fan Blades 46 Steering Tank & Lines + Check for: = Loose or damaged tank mounts & mounting bolts - Leaks at tank assembly seaing surface gasket nuts, bo Cracks, leaks ino ove sight glass Leaks at hycrauli fitr bases & line confections+ Make sure that breather is clean-and proper venta - Check by depressing the pressure rie ton on top of esther 4.7 Cab Extorior Check for: + Bent or damaged cab structure + Cracked or broken glass + Damaged or missing mirors + Wom or broken windshield wiper arm or wiper bade 4.8 Cab interior Check for: + Excessive clitin cab airfiter + Proper function of seat and seat belt + Wear or damage to seatbelt + Seat bet replacement date + Proper function of door and latches + Wom or broken window latches orsies + Damaged or inoperable gauges and controls 49.¢ab Mounts Check for: + Loose or damaged bots + Womn or damaged rubber mounts 4.10 Upper & Lowor Radiator Lines, Airinlot Lines, and tercooler Lines Check for: + Rubbing, cracked, or damaged hoses + Loose, over-tahtened, damaged hose camps 4.11 Radiator Gap + the radiators co0, check the radiator cap gaskets for wear or for damage 4.12 Hydraulic Pump Compartment check fr + Leaks around hose connertion points + Rubbing, damaged, or wom hoses + Loose or damaged hose clamps on pump suction lines + Rubbing, damaged, or worn wing harnesses or conneciors 4.19 Auto-Lube Pump, Tank, Injoctors Check for: + Leaks around connection points for hoses + Rubbing, damaged, or wor hoses + Rubbing, damaged, or wom wiring harnesses and cShnectors444 Rear Brake Lines & Components Inspect the following components: + Parking Brake Valve + TCS Conta! Valve + Rear Brake Slack Adjuster + Secondary Brake Pressure Switch + Brake Diverter (Towing) Vale located onthe left host elinder frame Suppet Check for: + Leaks around hose connections + Rubbing, damaged, or wom hoses + Rubbing, damaged, or wor wing harnesses or connectors 5.0 Implement/Attachment Inspections: 8:1 Hoist Cylinder Refer to Hydraulic Cylinder Inspection Guidetines” for inspection procedure Chock for: + Oil eaks indicated by dirt or ol buildup around telescopic rod & cinder lip seals + Oilleaks at hose connections + Damage to cinder rods + Damage or wear to tuck boy linkage pins & retainer patos + Grease leaking trom fame beating retainer, cap + Broken/damaged grease li 5, fitings 5.2 Truck Body Inspection Ccheck for excessive wear, structural damage, or weld cracks on: + Body liner + Canopy + Heated Body Exhaust Ports + Rock Ejactors Check for improper adjustment, excessive wear, or damage to: + Rocker Shoes, Rest Pads & Shims + Frame Rest Pads & Shims + Body Postion Sch Performance Checks Hydraulic Performance Checks Hoist Cylinder Tests Status Description ‘Specification | Actual [Comments Lif Cyele Time for Hoist Cylinders Table 8 "We Nomal M= Monto = Aston, Blank = Not AppoabieCylinder Drift Test Status” | Description | Specification [Aclual |Comments Oil Temperature Lif Cylinder Drift Table @ Steering Performance Checks Steering Turn Diameter Check Statue | Description | Specification [Actual | Commenta Full Steer Left |Full Steer Right Table 10 Brake Performance Checks status" Description ‘Specification [Actual | Comments ‘Service Brake Check (Test from OMM) Secondary Brake Check (Test from OMM) Parking Brake Check (Test from OMM) Rotardor Brake Check (Test from T&A) ‘Air Systom Warning Check (Test from T&A) Table 11 N= Nomi M = Mond, A Aton Blank = Not ApoB ip-11109208 2ozznane 01:18:50+08:00 109562703 (© 2022 Caterpilar Inc. 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