TA-1 Visual Inspection for Hydraulic Excavators

SMCS - Job Code - 540 Component Code - 753S

Cat dealer Customer

Address Address
Contact Contact

Serial Number : TYK00743 Inspector : jaxson Status: STOCK

Model : 304D Work Order : 117103709 Time :
Engine S/N: SMU: 3254 Date : 7/02/18
Manufacturer : CAT Required: 13/02/18 Unit Location: BCP

Note: Review Machine & S·O·S History and check for Active Service Letters prior to inspection.

Status of the Machine

The status recommendation of your excavator is: Normal
 Visual Inspection for Hydraulic Excavators
Status assessment ü– Normal M – Monitor A – Action Blank – Not Applicable

1. Inspection Preparation
# Status Description Comments
1.1 Normal Check with customer for operator complaints

1.2 Normal Perform machine inspection preparation

Download machine fault codes and upload ECM

1.3 Normal
configurations into SPI job.

1.4 Check Product Link

Is machine equipped with Product Link?

Is Product Link registered?

Is Product Link reporting to Vision Link?

1.5 Normal Observe engine exhaust colors

1.6 Normal Listen for unusual noises

1.7 Normal Lockout / Tagout Machine

1.8 Normal Check Product suport programs

1.9 Check Fire suppression system

Item No. Additional Comments

 2. Lower Level Inspection
# Status Description Comments
2.1 Normal Final drive & sprocket

2.2 Normal Travel Motor & brake valve

2.3 Action Track adjuster TRACKS NEED ADJUSTING

2.4 Normal Carrier rollers

2.5 Normal Track rollers

2.6 Normal Front idlers

2.7 Normal Track guides

2.8 Action Track shoes TRACKS WORN/ DAMAGED

2.9 Normal Track links, pins & bushings

2.10 Normal Track roller frame & carbody

2.11 Action Engine Oil Pan FRONT CRANK SEAL, FRONT HOUSING, SUMP LEAKING/REAR MAIN WASH AND ADVISE

2.12 Normal Belly plates

2.13

Item No. Additional Comments

 3. Middle Level Inspection
# Status Description Comments
3.1 Monitor Cab exterior PAINT FADED AND SCRATCHED

3.2 Action Cab interior SAFTEY AND INSTRUCTION STICKERS UNREADABLE, CAB SWITCHES ALL WORN AND NOT LABELED

3.3 Monitor Steps & handrails RUSTY AND MISSING PAINT

3.4 Normal Work lights

3.5 Action Air cleaner REPLACE AIR FILTERS

3.6 Action Batteries and battery cables BATTERY FLAT

3.7 Action Radiator, oil cooler, condenser & aftercooler OIL FILTER ADAPTOR AND HIOSES LEAKING

3.8 Normal Lower radiator & oil cooler hoses

3.9 Monitor Counterweight SCRATCHES ON COUNTERWEIGHT

3.10 Action Hydraulic pump compartment OIL ON TOP OF HYD PUMP WASH AND ADVISE

3.11 Normal Swing drive gear

3.12 Action Operation and maintenance manual OMM MISSING

3.13 Supplement for Lifting with Earthmoving Equipment Manual

3.14 Action Seat Belt Date and condition SEAT BELT OUT OF DATE

3.15 Wipers and washers

3.16 Level indicator

Item No. Additional Comments

ACTION MISSING TIE DOWN DECALS

ACTION PM STICKER FADED

ACTION HORN NOT WORKING

ACTION LHS PANEL BEHIND JOYSTICK BROKEN

 4. Upper-Level Inspection
# Status Description Comments
4.1 Normal Hood & platform

4.2 Normal Exhaust manifold

4.3 Normal Turbocharger

4.4 Action Cylinder head & valve cover ROCKER COVER LEAKING

4.5 Normal Engine mounts

4.6 Action Pulleys, belts & compressor clutch BELTS CRACKED

4.7 Normal Fan guard & fan

4.8 Normal Upper radiator, air inlet, oil cooler & after cooler lines

4.9 Normal Radiator/oil cooler screen

4.10 Normal Water pump

4.11 Normal Radiator cap

Fuel priming pump, secondary fuel filter & fuel injection
4.12 Normal
pump
4.13 Normal Engine wiring harness

4.14 Normal Swing drive compartment

4.15 Normal Swing drive

4.16 Normal Main hydraulic control valve

4.17 Action Beacon BEACON MISSING

4.18 AM/FM Radio

4.19 UHF Radio

4.2 Air contditioner temp Temp =

Item No. Additional Comments

ACTION CAB FLOOR MAT DAMAGED

ACTION DUE FOR 500HR SERVICE

 5. Implement/Attachment Inspection
# Status Description Comments
5.1 Action Area around boom cylinders & swivel BOOM CYLINDER HOSE DAMAGED /BENT FITTING

5.2 Action Lower boom area BOOM CYLINDER GUARD BENT

5.3 Normal Boom cylinder

5.4 Action Area where boom attaches to stick STICK- RHS TUBE BENT, RHS BULK HEAD BRACKET BENT, LHS HOSES DAMAGED

5.5 Normal Stick cylinder

5.6 Normal Bucket cylinder

5.7 Action Bucket linkage BUCKET LINKAGE NEEDS SHIMMING AT A MINIMUM

5.8 Normal Bucket wear plates

5.9 Normal Side cutters

5.10 Normal Tips & adapters

5.11 Action Quick hitch safety lock QUICK HITCH HOSES DAMAGED AND LEAKING

5.12 S.W.L decals eligible

5.13 Load check valves installed

Item No. Additional Comments

ACTION SEAT ADJUSTER SEIZED

ACTION ARM RESTS EXTRTEMLY FADED AND BRITTLE

ACTION ENGINE DOOR TOP SEAL MISSING

ACTION BOTH DOOR LATCHES NEED ADJUSTING

Other Remarks
 Hydraulic Excavator TA1 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. Inspection Preparation:

1.1 Check with customer for operator complaints

1.2 Perform machine inspection preparation
- Make sure no one is underneath the machine, around the machine, or on the machine. Be sure the area is free of personnel.
- Inspect under and around the machine for visible signs of fluid leaks
- Park the machine on a level surface in the recommended service position according to the OMM.
- Check engine oil, hydraulic oil, swing drive oil and eingine coolant levels. If necessary, add oil or coolant to reach minimum level.
1.3 Download Product Status Report
Download Product Status Report using ET.
If ET is not available, download fault codes using machine monitor.
1.4 Check Product Link
Is machine equipped with Product Link?
Is Product Link registered?
Is Product Link reporting to Vision Link?
1.5 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 grey smoke may indicate a fuel timing problem
1.6 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
1.7 Lockout / Tagout Machine
Turn the key start switch to the OFF position, remove the key, also remove the battery disconnect key and tag the machine out for safety.
 2. Lower-Level Inspections:

2.1 Inspect final drives and sprockets

Check the oil level in the final drives
If equipped, check the magnetic plug for metal particles
If the oil level is low, check the following areas for leaks:
Sealing surface between the cover and the ring gear
Sealing surface between the ring gear and the housing
Duo-cone seal located behind the sprocket
Inspect the sprockets
Look for broken or chipped teeth
Look for sharp edges on sprocket teeth; sharp edges on teeth indicate excessive sprocket wear
2.2 Inspect travel motors and brake valves
Check for oil leakage along the bottom surface of travel motor housing
If oil is visible in this area, remove the cover and inspect the travel motor, brake valve, and oil lines for leakage
2.3 Inspect track adjusters
Check for proper adjustment of track
If track adjustment is necessary, inspect the track adjuster

Look for grease and dust buildup around the piston; leakage in this area indicates piston lip seal or piston rod may be worn or damaged
Check track adjuster grease fitting for damage
2.4 Inspect carrier rollers for:
Oil leakage in the following areas:
On the sealing surface between the front cover and the roller
From the duo-cone seal located on the backside of the carrier roller
Excessive wear on the surface where the track link rides on the carrier roller
2.5 Inspect track rollers for:
Oil leakage in the following areas:
From the duo-cone seals located on the front and backside of the track roller
At each end of the track roller shaft; leakage in this area indicates the O-ring seal located on the track roller shaft may worn or
damaged
Excessive wear on the surface where the track link rides on the track roller
2.6 Inspect front idlers for:
Oil leakage from the following areas:
From the duo-cone seals located on the front and backside of the idler

At each end of the track idler shaft; leakage in this area indicates the O-ring seal located on the shaft may be worn or damaged
Excessive wear on the surfaces of the idler where the track link rides on the idler
2.7 Inspect the track guides for:
Damaged, missing, or loose bolts
Damage to track guide
2.8 Inspect the track shoes for:
Damaged, missing, or loose bolts
Damaged or worn track shoes
2.9 Inspect track links, pins, and bushings for:
Damaged or missing cotter pins in the master links
Excessive wear on contact surface of track links
Excessive noise in the track during machine operation
If excessive noise is noticed, check for temperature variances between the pins. To do this, touch the end of the pins with your
hand or use an infrared thermometer. Large temperature variances may indicate a dry joint in the link.
2.10 Inspect the track roller frames and carbody for:
Damage to frame
Structural cracks
Cracked welds
2.11 Inspect engine oil pan for:
Oil accumulation on the bottom of the oil pan. If oil is found on the pan, remove the bottom guard and inspect the following:
Check for leaks around the oil pan mounting flange
Check for leaks around the oil level sensor, drain valve, and the dipstick tube
Check the wiring harnesses and hoses located in the engine compartment for wear and/or damage

3. Middle-Level Inspections:

3.1 Inspect the cab exterior for:

Bent or damaged cab structure
Cracked or broken glass
Damaged or missing mirrors
Worn or broken windshield wiper arm or wiper blade
3.2 Inspect the cab interior for:
Excessive dirt in cab air filter
Proper function of the 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
3.3 Inspect steps and 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
3.4 Inspect work lights for:
Proper operation
Cracked or broken lenses
Damaged harnesses or electrical connectors
Loose or damaged mounting brackets
3.5 Inspect air cleaner for:
Dirt and/or debris in the air pre-cleaner
Loose or damaged hose clamps on air inlet tube
3.6 Inspect battery and battery cables for:
Corrosion on battery posts and/or cables
Proper function and tightness of battery hold down
3.7 Inspect radiator, oil cooler, condenser, and aftercooler for:
Plugged cores
Plugged screens
Damaged fins
3.8 Inspect lower radiator and oil cooler hoses for:
Rubbing, cracked, or damaged hoses
Loose or damaged hose clamps
3.9 Inspect counterweight for:
Damaged, missing, or loose bolts
3.10 Inspect hydraulic pump compartment for:
Leaks around hose connection points
Rubbing, damaged, or worn hoses
Rubbing, damaged, or worn wiring harnesses or connectors
Loose or damaged hose clamps on main pump suction lines
3.11 Inspect swing drive gear for:
Proper lubrication
Wear on visible gear teeth
Water in compartment
If compartment is full of water, remove the drain plate located above the bottom guard in the center of the carbody

4. Upper-Level Inspections:

4.1 Inspect hood and platform for:

Proper function of hood and latches
Debris or excessive dirt on service platform
4.2 Inspect exhaust manifold for:
Black soot around the sealing surface where the exhaust manifold bolts to the engine block, which may indicate:
Loose connection at the joint
Loose or broken manifold bolts
Cracks or other damage in the manifold housing
4.3 Inspect turbocharger for:
Black soot around the areas where the turbocharger bolts to the exhaust manifold or to the pipe, which would indicate:
Loose connection at the joint
Loose or broken mounting bolts
Oil leakage around the turbocharger oil line
Loose or damaged hose clamp on air inlet tube
4.4 Inspect cylinder head and valve cover for:
Oil and dust buildup around the valve cover sealing surface, which could indicate:
Loose connection at the joint
Damaged gasket or seal
Fuel leaks around and below the protective guard located above the fuel lines. If fuel leaks are present on the intake manifold, remove the
guard and inspect fuel lines for leaks.
4.5 Inspect engine mounts for:
Loose or damaged bolts
Wear or damage to rubber mounts
4.6 Inspect belts, pulleys, and compressor for:
Worn, cracked, or broken belts
Proper belt tension
Oil leaks around air conditioning compressor clutch
4.7 Inspect fan guard and fan for:
Loose, damaged, or missing bolts
Damaged wire fan guard
Cracked or missing blades on the engine fan
4.8 Inspect upper radiator, air inlet, oil cooler, and aftercooler lines for:
Rubbing, cracked, or damaged hoses
Loose or damaged hose clamps
4.9 Inspect radiator/oil cooler screen for:
Debris on the screen; clean if necessary
Holes and/or tears in the screen
4.10 Inspect water pump for:
Coolant leaks around water pump mounting flange
Coolant leaks through the weep hole in the water pump housing
4.11 If the radiator cap is cool, check:
Gaskets for wear or damage
4.12 Inspect fuel priming pump, fuel lines, and fuel injection pump for:
Damaged, rubbing, or worn fuel lines
Loose connections
4.13 Inspect engine harness for:
Loose or damaged wires
4.14 Inspect swing drive compartment for:
Leaks around hose connection points
Rubbing, damaged, or worn hoses
Rubbing, damaged, or worn wiring harnesses or connectors
4.15 Inspect swing drive:
Check the swing drive oil level; if the oil level is low, check the following areas for leaks:
Sealing surface between the cover and the ring gear
Sealing surface between the ring gear and the housing
Joint where the dipstick tube connects to the swing drive housing
If no leakage is found in these areas, leakage may be caused from a worn pinion shaft or bottom cover seal. To service these
seals, the swing drive must be removed.
4.16 Inspect the main hydraulic control valve for:
Leaks around hose connection points
Rubbing, damaged, or worn hoses
Rubbing, damaged, or worn wiring harnesses or connectors

5. Implement/Attachment Inspections: (Prior to inspection, extend the stick, open the bucket, and lower the boom.)

5.1 Inspect area around boom cylinders and swivel for:

Leaks around hose connection points
Rubbing, damaged, or worn hoses
Rubbing, damaged, or worn wiring harnesses or connectors
Boom cylinder linkage pin wear (refer to “Pin Inspection Guidelines” for inspection procedure)
5.2 Inspect lower boom area for:
Leaks around hose connections
Rubbing, damaged, or worn hoses
Damaged or leaking grease lines
Inspect boom foot pin (refer to “Pin Inspection Guidelines” for inspection procedure)
5.3 Inspect boom cylinder (refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure) 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)
5.4 Inspect area where boom attaches to stick for:
Leaks around hose connections
Rubbing, damaged, or worn hoses
Damaged or leaking grease lines
Inspect boom to stick pin and bucket cylinder pin (refer to “Pin Inspection Guidelines” for inspection procedure)
5.5 Inspect stick cylinder (refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure) for:
Oil leaks indicated by dirt or oil buildup around the cylinder lip seal
Oil leaks at hose connections
Damage to cylinder rods
Damage to wear to linkage pins (refer to “Pin Inspection Guidelines” for inspection procedure)
5.6 Inspect bucket cylinder (refer to “Hydraulic Cylinder Inspection Guidelines” for inspection procedure) 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)
5.7 Inspect bucket linkage 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
5.8 Inspect bucket wear plates for:
Excessive wear
5.9 Inspect side cutters for:
Excessive wear
Loose, damaged, or missing bolts.
5.10 Inspect bucket tips and adapters for:
Excessive wear on the bucket tips
Damage to the bucket tip adapter
Damage or missing retainer pins
 6. Site Conditions

6.1 Ambient Temperature

NORMAL: -18° to 32°C (0° to 90°F)
MONITOR: - 32° to 46°C or -18° to -29°C (90° to 115°F or 0° to -20°F
ACTION: Above 46°C or Below -29°C (Above 115° or Below -20°F)
6.2 Altitude
NORMAL: 0 to 1524 m (0 to 5000 ft)
MONITOR: 1524 to 3048 m (5000 to 10,000 ft)
ACTION: Above 3048 m (Above 10,000 ft)
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