TA-1 Visual Inspection for

Electric Rope Shovel - Rope Crowd

SMCS - Job Code - 540 Component Code - 753S

Cat dealer Customer

Address Address
Contact Contact

Serial Number : Inspector : Temperature :

Model : Work Order : Time :
SMH: Date :
Manufacturer : Unit Location:

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 Electric Rope Shovel - Rope Normal
Crowd is:
 Visual Inspection for Electric Rope Shovel - Rope Crowd
Status assessment ü– Normal M – Monitor A – Action Blank – Not Applicable

1. Prepare Machine Inspection

# Status Description Comments
1.1 Check with customer for operator complaints

1.2 Perform safety/preparatory inspection

1.3 Download machine fault codes

1.4 Prepare the machine for the inspection

Insure that shovel is parked on level ground and

a safe distance away from highwall

Insure Dipper is on the ground

Insure that all brakes are set

Insure that controls are de-energized

1.5

1.6

1.7

1.8

1.9

Item No. Additional Comment

HIGH VOLTAGE! The machine trail cable carries a lethal voltage. Handle the cable in an approved manner with appropriate rubber gloves and insul
hooks or tongs.
 2. Lower-Level Inspection
# Status Description Comments
2.1 Trailing cable

2.2 LHS propel gearcase

2.3 RHS propel gearcase

2.4 LH crawler frames

2.5 LHS crawler belt

2.6 RHS crawler belt

2.7 Swing rack

2.8 LHS hoist oil cooler

2.9 Boarding stairs/ladder

2.10 Machinery house exterior

2.11 Exterior lights and ground level illumination

2.12 Dipper

2.13

2.14

2.15

Item No. Additional Comment

 3. Middle Level Inspection
# Status Description Comments
3.1 LH stairways, walkways and platforms

3.2 RH stairways, walkways and platforms

3.3 LH swing gearcase

3.4 RH swing gearcase

3.5 Crowd gearcase

3.6 Hoist gearcase

3.7 LH Hoist Ropes at Hoist Drum

3.8 RH Hoist Ropes at Hoist Drum

Air Compressor(s), Air lube system lubricators and Auto

3.9
Lube Systems

3.10 Air receiver condensate traps

3.11 Lube room

3.12 A-Frame

3.13 Interior lighting

3.14

3.15

3.16

3.17

3.18

3.19

3.20

Item No. Additional Comment

 4. Upper-Level Inspection
# Status Description Comments
4.1 Cab exterior

4.2 Cab interior

4.3 Stairways and walkways

4.4 Hoist ropes and suspension strands

4.5 Crowd Retract Rope System

4.6 A-Frame

4.7

4.8

4.9

Item No. Additional Comment

 5. Implement/Attachment Inspection
# Status Description Comments
5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

Item No. Additional Comment

6. Site Conditions
# Status Description
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 Shovel Floor Condition

NORMAL: Flat

MONITOR: Mild

ACTION: Steep

6.4 Loading Conditions

NORMAL: Loose Bank, Good Fracture, Good Fill Factor

 ACTION: Tight Material, Bad Fracture, Poor Fill Factor

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

6.13

6.14
6.15

Item No. Additional Comments

Other Remarks
or Electric Rope Shovel - Rope Crowd
Blank – Not Applicable

1. Prepare Machine Inspection

Comments

l voltage. Handle the cable in an approved manner with appropriate rubber gloves and insulated
hooks or tongs.
2. Lower-Level Inspection
Comments
3. Middle Level Inspection
Comments
4. Upper-Level Inspection
Comments
5. Implement/Attachment Inspection
Comments

6. Site Conditions
Other Remarks
 Electric Rope Shovel - Rope Crowd 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

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 personne
Walk around the machine and inspect underneath the machine for visible signs of fluid leaks
Check all hydraulic oil, transmission oil, and gear case oil levels; if necessary, add oil to reach the minimum level for each s
1.3 Download machine fault codes
Download machine fault codes using either of these methods:
Midas
Advisor (where applicable)
1.4 Prepare the machine for the inspection
Park the machine in a level place clear free of personnel and obstacles
Put the transmission in neutral
Apply the parking brake
Lower the work tools to the ground
Turn the start switch to the “OFF” position and remove the key

2 Lower-Level Inspections:

2.1 Trailing Cable Inspection

Inspect the trailing cable for cuts, abrasions and damage
Inspect the cable reel / stinger for any damage
Inspect the cable reel Hydraulic System (if equipped)
2.2 LHS Propel Gearcase Inspection
Inspect the LHS propel gearcase for loose or missing hardware, leaks or damage
 Inspect the LHS propel motor coupling for damage, grease leakage or debris build-up
Inspect the LH propel brake assembly for damage, wear or signs of overheating
Inspect the LHS propel tachometer coupling for damage or debris build-up
2.3 RHS Propel Gearcase Inspection
Inspect the RHS propel gearcase for loose or missing hardware, leaks or damage
Inspect the RHS propel motor coupling for damage, grease leakage or debris build-up
Inspect the RH propel brake assembly for damage, wear or signs of overheating
Inspect the RHS propel tachometer coupling for damage or debris build-up
2.4 LH Crawler Frames Inspection
Inspect areas around the LH crawler frames, under the house and rev-frame for broken lube lines, signs of leaks, hardware
Inspect all LH bearing and bushing relief locations for signs of fresh grease, but not excessive amounts
Inspect areas around the RH crawler frames, under the house and rev-frame for broken lube lines, signs of leaks, hardware
Inspect all RH bearing and bushing relief locations for signs of fresh grease, but not excessive amounts
2.5 LHS Crawler Belt Inspection
Inspect LHS crawler belt for:
Broken link pins
Missing lock pins
Broken crawler links
Chipped or cracked load rollers and take-up tumbler
Broken drive tumbler lugs
Excessive belt slack
Chipped or cracked upper rollers / cracked welds or worn upper slide shoes
Other deterioration
2.6 RHS Crawler Belt Inspection
Inspect RHS crawler belt for:
Broken link pins
Missing lock pins
Broken crawler links
Chipped or cracked loa
Broken drive tumbler lugs
Excessive belt slack
Chipped or cracked upper rollers / cracked welds or worn upper slide shoes
Other deterioration
2.7 Swing Rack Inspection
Check for debris or dirt build up that could interfere with operation
Check swing rack and rails/rollers for proper lubricant film
Check swing pinion guards/dirt scrapers for damage and broken bolts
Inspect LHS swing gear case for leaks
Inspect LHS swing gear case for broken upper mount bolts
Inspect LHS swing pinion bearings for evidence of spent grease
Inspect RHS swing gear case for leaks
Inspect RHS swing gear case for broken upper mount bolts
Inspect RHS swing pinion bearings for evidence of spent grease
2.8 LHS Hoist Oil Cooler Inspec
Inspect LHS hoist oil cooler for leaks, damage or dirt build-up
Inspect LHS HydraCrowd oil cooler for leaks, damage or dirt build-up
Inspect RHS HydraCrowd oil coolers for leaks, damage or dirt build-up
Inspect HydraCrowd oil cooler hoses for damage or leaks
2.9 Boarding Stairs/Ladder Inspection
Inspect boarding stairs/ladder for damage, hazards and proper function
Check boarding stairs/ladder for secure latching in stowed position
2.10 Machinery House Exterior Inspection
2.11 Exterior Lights and Ground Level Illumination Inspection
2.12 Dipper
Inspect the dipper teeth and teeth adaptors for missing or worn hardware
Inspect dipper body for cracks and deformations
Inspect dipper door, bumpers and other hardware for damage and wear
Inspect dipper trip mechanism, latch bar, rope and associated hardware for damage
Inspect padlocks for damage or wear
 Inspect dipper handle for damage, wear and adequate lubrication
Visually inspect crowd and retract ropes for damage or broken wires
Inspect boom bumper for security and damage
Inspect LH Hoist Rope at Dipper
Measure LT Hoist Rope Diameter
Inspect snubbers for tightness
Inspect RH Hoist Rope at Dipper
Measure RI Hoist Rope Diameter

3 Middle-Level Inspections:

3.1 LH Stairways, Walkways and Platforms Inspection

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
3.2 RH Stairways, Walkways and Platforms Inspection
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
3.3 LH Swing Gearcase Inspection
Inspect the LH swing gearcase for oil level and leaks
Inspect the LH swing motor coupling for damage or grease leakage
Inspect the LH swing brake assembly for damage, wear or signs of overheating
3.4 RH Swing Gearcase Inspection
Inspect the RH swing gearcase for oil level and leaks
Inspect the RH swing motor coupling for damage or grease leakage
Inspect the RH swing brake assembly for damage, wear or signs of overheating
3.5 Crowd Gearcase Inspection
Visually inspect the crowd motor coupling for damage or grease leakage
Visually inspect the crowd machinery for loose bolts, nuts, clamps or any other damage
Visually inspect the crowd brake assembly for damage, wear or signs of overheating
Inspect the open gears on the crowd machinery for proper lubrication
Verify presence of spent lube at all grease reliefs
3.6 Hoist Gearcase Inspection
Inspect the hoist gearcase for oil level and leaks
Inspect the hoist motor coupling for damage or grease leakage
Iinspect the hoist brake assembly for damage, wear or signs of overheating
Inspect the hoist machinery for loose bolts, nuts, clamps or any other damage
Inspect the open gears on the hoist machinery for proper lubrication
Verify presence of spent lube at all grease reliefs on hoist gearcase and at hoist drum bearings
Check hoist ropes at ferrule anchors for signs of birdcaging, rotation or pull out of rope from ferrule button
3.7 LH Hoist Ropes at Hoist Drum Inspection
Check LH Hoist Ropes at Hoist Drum
Check LH Hoist Rope Diameter
Check that LH hoist ropes are properly seated in the grooves of the hoist drum
3.8 RH Hoist Ropes at Hoist Drum Inspection
Check RH Hoist Ropes at Hoist Drum
Check RH Hoist Rope Diameter
Check that RH hoist ropes are properly seated in the grooves of the hoist drum
3.9 Air Compressor(s), Air Lube System Lubricators and Auto Lube Systems Inspection
3.10 Air Receiver Condensate Traps Inspection
Check air receiver condensate traps for proper function
Check air system dryer (if equipped) for proper function
3.11 Lube Room Inspection
 Check lube pumps for any signs of malfunctioning
Check lube level in OGL tank
Check lube level in Hoist Gear OGL tank (if equipped)
Check lube level in MPG tank
Inspect condition of all lube hoses, lines and injectors to insure no leakage
3.12 A-Frame Inspection
Check pins and keepers on front (2) and rear (2) leg mounts
Check for cracks
3.13 Interior Lighting Inspection
Check all lights and swithes for proper operation

4 Upper-Level Inspections:

4.1 Cab Exterior Inspection

Check for bent or damaged cab structure
Check for cracked or broken glass
Check for damaged or missing mirrors
Check for worn or broken windshield wiper arm or wiper blade
4.2 Cab Interior Inspection
Check for excessive dirt in cab air filter
Check horn operation
Check for proper function of seat and seat belt
Check for wear or damage to seat belt
Check for seat belt replacement date
Check for proper function of door and latches
Check for worn or broken window latches or slides
Check for damaged or inoperable gauges and controls
Check for properly functioning backup alarm
Check operator HMI screens for proper operation
Check video monitors and cameras for proper operation
Check mine radio operation
Check fire extinguisher for damage, charge, seal, and inspection tag
4.3 Stairways and Walkways Inspection
Inspect stairways and walkways for obstructions, hazards or damage
Inspect roof hand rails and camera mounts for damage
Inspect house blowers and filtration system for damage
4.4 Hoist ropes and suspension strands Inspection
Inspect the hoist ropes and suspension strands for broken wires
Inspect hoist rope guide rollers for damage and adequate lubrication of bearings
Inspect the dipper trip motor assembly, rope and guide sheaves for damage
4.5 Visually inspect Crowd Retract Rope System
Check rear half of dipper handle for adequate lubricant film
Visually check lube hoses at saddle block for damage
Visually inspect the Crowd rope for broken wires
Visually check greenhorn bolted connection to handle for broken / missing bolts
Visually check bellows at crowd takeup screw for damage
4.6 A-Frame Inspection
Check pins and keepers on equalizers/suspension strand sockets

5 Implement/Attachment Inspections:
e of personnel

evel for each system

aks, hardware or defects

eaks, hardware or defects

 Performance Checks for Electric Rope Shovel - HydraCrowd
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

Crowd Extend slowdown and stop limit

Crowd Retract slowdown and stop limit

Hoist Raising slowdown and stop limit

Hoist Lowering slowdown and stop limit