TA1 English - Dragline

TA-1 Visual Inspection for Dragline
SMCS - Job Code - 540 Component Code - 753S
Cat Dealer: Customer:

Address: Address:
Contact: Contact:
Serial Number: Inspector: Temperature (C/F):
Model: Work Order: Time:

Manufacturer: DLMH: Date:
Unit Location:
Note: Review Machine & S·O·S History and check for Active Service Letters prior to inspection.
Status of the Machine

Normal
The status recommendation of your Dragline is:
Visual Inspection for Dragline
Status assessment ü– Normal M – Monitor A – Action Blank – Not Applicable
1. Prepare Machine Inspection

# Status Description Comments
Check with customer for operator complaints, review
1.1
prior daily inspections and record
1.2 Perform safety/preparatory inspection
1.3 Record machine fault codes
1.4 Prepare the machine for the inspection
Insure that dragline is parked on level ground

and a safe distance away from highwall
Insure Bucket is on the ground
Insure that all brakes are set
Insure that controls are de-energized
1.5 Lock out machine per Mine Procedures
1.6
Item No. Additional Comments
HIGH VOLTAGE! The machine trail cable carries a lethal voltage. Handle the cable in an approved manner with appropriate rubber gloves and insulated
hooks or tongs.
2. Lower-Level Inspection (Base/Tub)
2.1 Trailing cable
2.2 Tub
2.2.1 Outside Structure
2.2.2 Inside Structure
2.2.3 Manhole Covers
2.2.4 Hook Shoes
2.2.5 Hook Rail
2.3 Rails and Rollers
2.4 Swing Rack
2.5 General
2.6
2.7

3. Revolving Frame Inspection
3.1 Revolving Frame
3.1.1 Inside Structure
3.1.2 A-leg Anchors
3.1.3 Mast and Boom Foot Lugs
3.1.4 Center Pintle
3.1.5 Manhole Covers
3.1.6 Handrails, Toe plates, Safety Devices
3.2
3.3

4. House Inspection
4.1 House
4.1.1 Superstructure
4.1.2 Crane Rails and Beams
4.1.3 House Panels
4.1.4 Rope Deflection Tower (if equipped)
4.1.5 Drag Pan Sheaves or Rollers (if equipped)
4.1.6 Filter House
4.2
4.3

5. Fairlead Inspection
5.1 Fairlead
5.1.1 Structure
5.1.2 Swivel Frame
5.1.3 Guide Rollers
5.1.4 Sheaves
5.1.5 Lube Lines
5.1.6 Buffer Cylinders
5.1.7 Limit Cables
5.2
5.3

6. Shoe Inspection
6.1 Right Shoe
6.2 Right Walking Equipment
6.3 Left Shoe
6.4 Left Walking Equipment
6.5
6.6

7. A-frame Inspection
7.1 A-Frame
7.1.1 Rear and Front Mounting Lugs
7.1.2 Rear Leg Failures
7.1.3 Safety Cables
7.1.4 Suspension Ropes
7.1.5 Legs
7.1.7 Pressurization System
7.2
7.3

8. Gantry Inspection (if equipped)
8.1 Gantry
8.1.1 Structural Members
8.1.2 Suspension Links
8.1.3 Sheaves
8.2
8.3

9. Mast Inspection (if equipped)
9.1 Mast
9.1.1 Chords and Lacing
9.1.2 Intermediate Suspension Brackets
9.1.3 Mast Head Structure
9.1.5 Suspension Strands
9.1.6 Reeving Sheaves
9.2
9.3

10. Tri-structure (if equipped)
10.1 Tri-structure
10.1.2 Intermediate Suspension Brackets
10.1.3 Mast Head Structure
10.1.6 Reeving Sheaves
10.2
10.3

11. Boom Inspection
11.1 Boom
11.1.2 Point Box Structure
11.1.3 Point Sheaves
11.1.4 Point Swivel
11.1.5 Deflection Tower Sheaves
11.1.6 Suspension Bolts
11.1.7 Lubrication
11.1.8 Deflection Tower Structure
11.2
11.3

12. Swing Machinery Inspection
12.1 Number 1 Swing
12.2 Number 2 Swing
12.3 Number 3 Swing
12.4 Number 4 Swing
12.5 Number 5 Swing (if equipped)
12.6 Note: If additional Swing equipment, add additional lines
12.7
12.8

13. Hoist Machinery Inspection
13.1 Right Hoist Machinery
13.2 Left Hoist Machinery
13.3 Confirm Oil Levels
13.4

14. Drag Machinery Inspection
14.1 Right Drag Machinery
14.2 Left Drag Machinery
14.3 Confirm Oil Levels
14.4

15. Propel Machinery Inspection
15.1 Right Propel Machinery
15.2 Left Propel Machinery
15.3
15.4

16. Electrical Inspection
16.1 Electrical
16.1.1 Brushes
16.1.2 Commutator Film
16.1.3 Fans and Blowers
16.1.4 Master Switches
16.1.5 House Heaters (if installed)
16.1.6 Lighting
16.1.7 Gear case and Cam Heaters
16.1.8 Climate Controls
16.1.9 Cranes
16.1.10 MG Sets
16.1.11 MCC's
16.1.12 Cooling Systems (MRC's)
16.2
16.3

17. Bucket Inspection
17.1 Bucket
17.2 Rigging
17.3 GET/Adapters
17.4
17.5

18. Other Inspection (if equipped)
18.1 Note any modifications that apply to this machine
18.2
18.3

19. Site Conditions
# Status Description
19.1 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)
19.2 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)
19.3 Dragline Pad Condition
NORMAL: Flat
MONITOR: Mild
ACTION: Steep
19.4 Loading Conditions
NORMAL: Loose Bank, Good Fracture, Good Fill Factor
ACTION: Tight Material, Bad Fracture, Poor Fill Factor
19.5 Humidity
NORMAL: Below 25%
MONITOR: 25 to 60%
ACTION: Above 60%
19.6 Air Quality
NORMAL: No Dust
MONITOR: Light Dust
ACTION: Heavy Dust
19.7 Underfoot Condition
NORMAL: Dry Flat Surface
MONITOR: Moderate Grades, Mixture of Muddy / Dry Surfaces
ACTION: Steep Grades, Muddy, Snow, Ice
19.8 Machine Utilization
Document hours per week
19.9 Working Material
NORMAL: Uncompacted, Low Abrasion
MONITOR: Moderately Compacted, Moderate Abrasion
ACTION: High Abrasion, Compacted, Dense
19.10 Maintenance Practices
NORMAL: Excellent
MONITOR: Good
ACTION: Poor
19.11 Primary Industries
19.12
19.13
19.14

Other Remarks
Dragline 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
1. Inspection Preparation:
1.1 Check with customer for operator complaints
Review the recent daily inspection sheets performed by the operator/maintenance personnel
1.2 Perform safety/preparatory inspection
Make sure no one is underneath the machine, around the machine, or on the machine; ensure the area is free of personnel
Walk around the machine and inspect underneath the machine for visible signs of fluid leaks
1.3 Download machine fault codes
Record machine fault codes
1.4 Prepare the machine for the inspection
Park the machine in a level place clear free of personnel and obstacles
Position Bucket so maintenance can be performed.
Set all brakes, shut excitation off, stop MG sets
Lock and Tag at proper locations
2. Lower-Level Inspections (Base/Tub):
2.1 Trailing Cable Inspection
Inspect the trailing cable for cuts, abrasions and damage
2.2 Tub
2.2.1 Inspect outside structure - broken welds
2.2.2 Inspect inside structure - center pintle NOTE: Follow Mine and Dealership Confined Space Procedures
Inspect inside structure welds (T-rails)
Note buckled support walls, bottom plates
2.2.3 Ensure manhole covers are in place
2.2.4 Inspect hook shoes for cracks and clearance
2.2.5 Inspect hook rail for scrubbing and cracked welds
2.3 Rails and Rollers
Inspect rails and rollers for proper lubrication
Inspect for worn or broken rollers
Inspect that roller thrust washers are in place
Inspect roller retaining bands
Inspect rail path for chock block tightness
Inspect rail wear
2.4 Swing Rack
Inspect swing rack for proper lubrication
Inspect swing rack for wear pattern
Inspect swing pinions for cracked or worn teeth
Inspect swing rack for bolt tightness
2.5 General
Ensure the automatic lube system is functioning properly
Inspect machine cleanliness
Inspect wear plates
Ensure all drain plugs are in place
3. Revolving Frame Inspections:
3.1 Revolving Frame
3.1.1 Inspect all compartments for cracking
Inspect for bent diaphragms
3.1.2 Inspect for cracking around rear A-leg anchor
3.1.3 Inspect for cracks in mast and boom foot lugs
3.1.4 Inspect center pintle bushing for excessive wear
Check clearance between center pintle bushing and clamp
Inspect for proper lubrication of center pintle
3.1.5 Ensure all manhole covers are in place
3.1.6 Ensure all handrails, toe plates and safety devices are in place
4. House Inspections:
4.1 House
4.1.1 Inspect Superstructure
4.1.2 Inspect Crane Rails and Beams
4.1.3 Inspect House Panels
4.1.4 Inspect Rope Deflection Tower (if equipped)
4.1.5 Inspect Drag pan Sheaves or Rollers (if equipped)
4.1.6 Filter Fans - Check bleed duct operation and filter fans for noise and vibration
5. Fairlead Inspections:
5.1 Fairlead
5.1.1 Inspect for cracked members and welds
5.1.2 Inspect swivel frame for damage
Inspect swivel frame for excessive movement
5.1.3 Inspect fairlead guide rollers for wear
5.1.4 Inspect for clearance and free rotation of sheaves
Inspect sheaves for wear
Check alignment between horizontal and vertical sheaves
5.1.5 Inspect all lube lines condition
5.1.6 Inspect buffer cylinders for correct operation
5.1.7 Inspect fairlead limit cables
6. Shoe/Walking Equipment Inspections:
6.1 Right Shoe
Inspect condition of shoe for cracks NOTE: Follow Mine and Dealership Confined Space Procedures
Inspect condition of cleats
Note any modifications that have been made
Does the timing of the shoes appear proper
Are handrails, toe plates and safety devices in place?
6.2 Right Walking Equipment
Inspect walking arms for cracks
Inspect cams for cracks
Inspect cam frames for cracks
6.3 Left Shoe

Inspect condition of shoe for cracks NOTE: Follow Mine and Dealership Confined Space Procedures
Inspect condition of cleats
Note any modifications that have been made
Does the timing of the shoes appear proper
Are handrails, toe plates and safety devices in place?
6.4 Left Walking Equipment
Inspect walking arms for cracks
Inspect cams for cracks
Inspect cam frames for cracks
7. A-frame Inspections:
7.1 A-frame
7.1.1 Inspect rear and front mounting lugs for cracks
7.1.2 Inspect for rear leg failures around pin connection
7.1.3 Inspect safety cables for rusting
7.1.4 Inspect suspension ropes for broken wires
7.1.5 Inspect legs for cracks
7.1.6 Are handrails, toe plates and safety devices in place?
7.1.7 Is the pressurization system operational?
Record the PSI
8. Gantry Inspections (if equipped):
8.1 Gantry
8.1.1 Inspect all structural members on gantry head for cracking
8.1.2 Inspect suspension links for cracking and bushing damage
8.1.3 Inspect upper and lower support sheaves bushing condition
Inspect reeving sheaves for free rotation and lubrication
9. Mast Inspections:
9.1 Mast
9.1.1 Inspect all chord members and lacings for cracking
9.1.2 Inspect upper and lower intermediate suspension brackets
9.1.3 Inspect all structural members on mast head for cracking
9.1.5 Inspect suspension strands for broken wires, rust, etc.
Does customer X-ray strands?
9.1.6 Inspect reeving sheaves for free rotation and lubrication
Record the PSI
10. Tri-structure Inspections (if equipped):
10.1 Mast
10.1.1 Inspect all chord members and lacings for cracking
10.1.2 Inspect upper and lower intermediate suspension brackets
10.1.3 Inspect all structural members on mast head for cracking
10.1.5 Inspect suspension strands for broken wires, rust, etc.
Does customer X-ray strands?
10.1.6 Inspect reeving sheaves for free rotation and lubrication
11. Boom Inspections:
11.1 Boom
11.1.1 Inspect all boom chords and lacings for cracks
11.1.2 Inspect boom point box structure for cracks
11.1.3 Inspect condition of point sheaves
11.1.4 Inspect that point swivel thrust washers are in place
11.1.5 Inspect the adjustment of the deflection tower sheaves
11.1.6 Inspect suspension bolts for cracks and damage
11.1.7 Inspect for proper lubrication of all sheaves
Inspect for proper operation of the lube system to boom
11.1.8 Inspect structural members of deflection towers
11.1.9 Inspect boom suspension strands for corrosion, rust, etc.
Inspect for broken wires on strands (record number)
Does the customer X-ray the strands?
Record the PSI on all systems.
12. Swing Machinery Inspections:
12.1 Number 1 Swing
Inspect case to floor welds for cracks
Check for any excessive vibration or noise while operating
Inspect swing gear wear pattern
Inspect swing gears for proper lubrication
Inspect retainers for cracks or leaking oil
Inspect for proper lubrication of lower pinions
Inspect brake hardware for wear
Has swing shaft been UT inspected regularly?
What were the results of the last inspection?
Note problems with vertical shaft retainer plates
Note any oil leaks
12.2 Number 2 Swing
Note any oil leaks
12.3 Number 3 Swing
Note any oil leaks
12.4 Number 4 Swing
Note any oil leaks
12.5 Number 5 Swing (if equipped)
Note any oil leaks
Note: If additional Swing equipment, copy the above for each case
13. Hoist Machinery Inspections:
13.1 Right Hoist Machinery
Inspect gears and pinions for wear pattern
Check brake hardware for wear
Visually inspect drum
Have the spiders been UT inspected regularly?
Note any oil leaks
Inspect Pedestal for cracks
13.2 Left Hoist Machinery
Note any oil leaks
14. Drag Machinery Inspections:
14.1 Right Drag Machinery
Note any oil leaks
14.2 Left Drag Machinery
Note any oil leaks
15. Propel Machinery Inspections:
15.1 Right Propel Machinery
Inspect upper and lower gears for wear pattern
Inspect gears for proper lubrication
Check for proper lubrication of cam and guide
Check automatic lube system for proper operation
Has the camshaft been UT inspected regularly?
Note any oil leaks
15.2 Left Propel Machinery
Inspect upper and lower gears for wear pattern
Inspect gears for proper lubrication
Check for proper lubrication of cam and guide
Check automatic lube system for proper operation
Has the camshaft been UT inspected regularly?
Note any oil leaks
16. Electrical Inspections:
16.1 Electrical
16.1.1 Inspect brushes for wear and sparking, both motors and generators
16.1.2 Inspect commutator film, both motors and generators
16.1.3 Inspect Ventilation Fans and Blowers, Motor Blowers, Intake and Exhaust Fans
16.1.4 Check Master Switches - proper operation and freedom of movement
16.1.5 Inspect all House Heaters (if installed)
16.1.6 Inspect all House and Boom Lighting
16.1.7 Inspect all Gear case and Cam Heaters (if installed)
16.1.8 Inspect and test all climate controls for operators cab and control room.
16.1.9 Inspect Operation of Cranes
16.1.10 Check for vibration in MG sets
Check for bearing noise in MG set
Check oil levels in pedestals
16.1.11 Inspect MCC's
16.1.12 Inspect Cooling Systems (MRC's)
17. Bucket:
17.1 Bucket
Trunnion connect points - Inspect for cracks LH and RH
Arch structure - Inspect for cracks
Corner castings - Inspect for cracks
Lip casting - Inspect for cracks
Wear plates - Inspect material remaining
Bucket heel casting - Inspect wear
Basket structure - Inspect for cracks
17.2 Rigging
Hoist Chain - Upper / Lower - Inspect for twists and cracks
Drag Chain - Inspect for twists and cracks
Wire Rope - Sockets/connections - Inspect condition of rope and connections
Spreader Bar Assemblies - Upper/Lower - Inspect for cracks
Dump rope rigging - Inspect condition of chain
Wire rope dump line - Inspect condition of anchor
Lubrication - bucket rigging - verify distribution
17.3 GET/Adapters
Teeth - Inspect for excessive wear, damaged and missing
Adapters - Inspect for damaged, cracked and missing
18. Other Inspections (if equipped):
18.1 Note any modifications that apply to this machine
Rat hole eliminators
360 Rack pad
Rack pad diaphragms
Rear A-leg doublers
Rear A-leg anchor hub
Additional shoe trunnion bolts
Shoe trunnion extension plates
Lower swing bearing plate
Boom foot anchor
Mast foot anchor
Safety cable anchor plate extension
Boom point box UMS lugs
Pulled back lacing at C-chord
New style suspension links
Intermediate suspension strand rod bolts
Reduced sump swing filtration system
Performance Checks for Dragline
Status assessment ü- Normal M - Monitor A - Action Blank – Not Applicable
1. Performance Checks
1.1 Performance Checks
Status Description Units Observed Max Min Comments
1.1.1 Slowdown and Stop Limit
Drag slowdown and stop limit
Hoist slowdown and stop limit
Check Propel limits
1.1.2 Fairlead
Inspect Area of Pins for Excessive Movement Under

Load
1.1.3 Gantry
Inspect Gantry Foot Pins for Excessive Movement
Under Load
1.1.4 Mast
Inspect Mast Foot Pins for Excessive Movement Under
Load
1.1.5 Electrical
Check exciter volts
Check current for motor fields on all motions
Check armature current during operation on Hoist, Drag

and Swing
Check armature volts during operation on Hoist, Drag
and Swing
Do XY Plot of all motions
1.1.6 Brake Check
Hoist
Drag
Swing
Propel
1.1.7 Lube System
Check for proper operation while running
Check for excessive leaks
1.1.8 Air System
Check for proper operation while running
Check for excessive compressor cycling

TA1 English - Dragline

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TA1 English - Dragline

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TA-1 Visual Inspection for Dragline

SMCS - Job Code - 540 Component Code - 753S

Cat Dealer: Customer:

Serial Number: Inspector: Temperature (C/F):

Model: Work Order: Time:

Status of the Machine

1. Prepare Machine Inspection

1.3 Record machine fault codes

1.4 Prepare the machine for the inspection

Insure that dragline is parked on level ground

Insure Bucket is on the ground

Insure that all brakes are set

Insure that controls are de-energized

1.5 Lock out machine per Mine Procedures

Item No. Additional Comments

2.2.1 Outside Structure

2.2.2 Inside Structure

2.2.3 Manhole Covers

2.2.4 Hook Shoes

2.2.5 Hook Rail

2.3 Rails and Rollers

2.4 Swing Rack

Item No. Additional Comments

3.1.1 Inside Structure

3.1.2 A-leg Anchors

3.1.3 Mast and Boom Foot Lugs

3.1.4 Center Pintle

3.1.5 Manhole Covers

3.1.6 Handrails, Toe plates, Safety Devices

Item No. Additional Comments

4.1.2 Crane Rails and Beams

4.1.3 House Panels

4.1.4 Rope Deflection Tower (if equipped)

4.1.5 Drag Pan Sheaves or Rollers (if equipped)

4.1.6 Filter House

Item No. Additional Comments

5.1.2 Swivel Frame

5.1.3 Guide Rollers

5.1.5 Lube Lines

5.1.6 Buffer Cylinders

5.1.7 Limit Cables

Item No. Additional Comments

6.2 Right Walking Equipment

6.3 Left Shoe

6.4 Left Walking Equipment

Item No. Additional Comments

7.1.1 Rear and Front Mounting Lugs

7.1.2 Rear Leg Failures

7.1.3 Safety Cables

7.1.4 Suspension Ropes

7.1.6 Handrails, Toe plates, Safety Devices

7.1.7 Pressurization System

Item No. Additional Comments

8.1.1 Structural Members

8.1.2 Suspension Links

8.1.4 Handrails, Toe plates, Safety Devices

Item No. Additional Comments

9.1.1 Chords and Lacing

9.1.2 Intermediate Suspension Brackets

9.1.3 Mast Head Structure

9.1.4 Suspension Links

9.1.5 Suspension Strands

9.1.6 Reeving Sheaves