TA-1 Visual Inspection for Hydraulic Excavators

SMCS - Job Code - 540 Component Code - 753S

Cat dealer Customer

Address Address
Contact Contact

Serial Number : Inspector : Temperature :

Model : Work Order : Time :
Engine S/N: SMU: Date :
Manufacturer : 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 excavator is:
 Visual Inspection for Hydraulic Excavators
Status assessment ü– Normal M – Monitor A – Action Blank – Not Applicable

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

1.2 Perform machine inspection preparation

1.3 Download Product Status Report

1.4 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

1.6 Listen for unusual noises

1.7 Lockout / Tagout Machine

1.8

1.9

Item No. Additional Comments

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

2.2 Travel Motor & brake valve

2.3 Track adjuster

2.4 Carrier rollers

2.5 Track rollers

2.6 Front idlers

2.7 Track guides

2.8 Track shoes

2.9 Track links, pins & bushings

2.10 Track roller frame & carbody

2.11 Engine Oil Pan

2.12

2.13

Item No. Additional Comments

 3. Middle Level Inspection
# Status Description Comments
3.1 Cab exterior

3.2 Cab interior

3.3 Steps & handrails

3.4 Work lights

3.5 Air cleaner

3.6 Batteries and battery cables

3.7 Radiator, oil cooler, condenser & aftercooler

3.8 Lower radiator & oil cooler hoses

3.9 Counterweight

3.10 Hydraulic pump compartment

3.11 Swing drive gear

3.12

3.13

3.14

Item No. Additional Comments

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

4.2 Exhaust manifold

4.3 Turbocharger

4.4 Cylinder head & valve cover

4.5 Engine mounts

4.6 Pulleys, belts & compressor clutch

4.7 Fan guard & fan

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

4.9 Radiator/oil cooler screen

4.10 Water pump

4.11 Radiator cap

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

4.14 Swing drive compartment

4.15 Swing drive

4.16 Main hydraulic control valve

4.17

4.18

4.19

Item No. Additional Comments

 5. Implement/Attachment Inspection
# Status Description Comments
5.1 Area around boom cylinders & swivel

5.2 Lower boom area

5.3 Boom cylinder

5.4 Area where boom attaches to stick

5.5 Stick cylinder

5.6 Bucket cylinder

5.7 Bucket linkage

5.8 Bucket wear plates

5.9 Side cutters

5.10 Tips & adapters

5.11

5.12

5.13

Item No. Additional Comments

 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 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

6.12 Primary Industries

6.13

6.14

6.15

Item No. Additional Comments

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
ACTION: or 0°
Above to -20°F
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
 Performance Checks for Hydraulic Excavators
Status assessment ü- Normal M - Monitor A - Action Blank – Not Applicable / Not Performed (Add reason in comments)

1. Performance Checks
1.1 Hydraulic Performance Checks
Status Description Units Observed New Rebuild Service Comments
Limit
1.1.1 1.1.1 Travel on Level Ground
Travel on Level Groun
Travel Speed - Check

Travel Distance

High Forward

High Reverse

Low Forward

Low Reverse
Low Reverse
Travel Deviation - Check

High Forward

High Reverse

Low Forward

Low Reverse
1.1.2
1.1.2 Travel on Level Ground - Test (Optional Test)
Travel on Level Ground
Travel Speed (Right Track) - Check (With track raised)

High-Forward

High Reverse

Low Forward

Low Reverse
Low Reverse
Travel Speed (Left Track) - Check (With track raised)

High Forward

High Reverse

Low Forward

Low Reverse

1.1.3 Machine Drift on a Slope - Check

1.1.4
1.1.4 Swing Speed and Overswing on Level Ground - Check

Swing Speed (Right Swing)

Swing Speed (Left Swing)

Over Swing (Right Swing)

Over Swing (Left Swing)

 Status Description Units Observed New Rebuild Service Comments
Limit
1.1.5 1.1.5 Swing Speed and Swing Drift on a Slope -Check

Swing Speed (Right Swing)

Swing Speed (Left Swing)

Swing Drift (Right Swing)

Swing Drift (Left Swing)

1.1.6
1.1.6 Cylinder Drift - Check (Loaded Bucket)

Weight of Bucket Load

Boom Cylinder

Stick Cylinder

Bucket Cylinder
1.1.7
1.1.7 Cylinder Drift - Check (Empty Bucket)

Boom Cylinder

Stick Cylinder

Bucket Cylinder
1.1.8
1.1.8 Cylinder Speed - Check

Boom Extension

Boom Retraction

Stick Extension

Stick Retraction

Bucket Extension

Bucket Retraction