302.5 Excavator TA2 Technical Inspection{0372, 1000, 7000, 753T, 7565}
- Mini Hydraulic Excavator:
- 302.5 (S/N: 4AZ1-UP)
Introduction
Inspections are the most basic form of condition monitoring. Inspections are easy to do and surprisingly effective at helping you spot equipment health issues. Proactive monitoring and analysis of equipment information will allow Dealers to intervene effectively before problems occur.
Note: Before adjusting product settings to comply with listed baseline TA2 values, consult SIS for the latest specification values.
Note: Specification values are based on the following machine settings unless stated otherwise
- Engine Speed High Idle
Creating an Electronic Copy
Use the following procedure to create an editable electronic copy from SIS Web.
- Click format to print.
- Save the document as an HTML format.
- Open the document with Microsoft Word.
Electrical System
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| Status (1) | Description | Specification | Actual | Comments |
| Inspect Battery Cables | Cables between the battery, the starter, and the engine ground must be the correct size. Wires and cables must be free of corrosion. Wires and cables must have cable support clamps in order to prevent stress on battery connections (terminals). | |||
| Battery Test (2) | 12.4 VDC or more | |||
| Charging System Test (3) | 12 VDC to 50 VDC | |||
| Electric Starting System Test (3) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
| ( 2 ) | Refer to Special Instruction, SEHS7633, "Battery Test Procedure". |
| ( 3 ) | Refer to General Service Manual, RENR5578, "Electrical System". |
Engine
Cooling System
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| Status (1) | Description | Specification | Actual | Comments |
|---|---|---|---|---|
| Radiator Pressure Relief (Radiator Cap) (2) | - | |||
| Freezing Point of Engine Coolant | - | Use 245-5829 Coolant/Battery Tester Gp . | ||
| Conditioner Test of Engine Coolant | - | Use 8T-5296 Coolant Conditioner Test Kit . | ||
| Belt Tension | 10.0 to 12.0 mm (0.39 to 0.47 inch) | Apply 98 N (22 lb) of force midway between the pulleys. |
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| Difference between the Upper Radiator Tank Temperature and Lower Radiator Tank Temperature | ||||
| Jacket Water Inlet Temperature from Cooling System | 95 °C (203 °F) |
Fully opened temperature. From Specifications, SENR5022, "3013 Engine for Caterpillar Built Machines", "Water Temperature Regulator". |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
| ( 2 ) | Test for the pressure that is listed on the cap. |
Fuel System
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| Status (1) | Description | Specification | Actual | Comments |
| Fuel System - Maximum Pressure | 42 to 70 kPa (6 to 10 psi) |
Minimum pressure is 31 kPa (4.5 psi). Obtain pressure reading by cranking engine for 10 seconds. Follow procedure Testing and Adjusting, SENR5023, "3013 Engine for Caterpillar Built Machines", "Fuel System Pressure". |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Lubrication System
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| Status (1) | Description | Specification | Actual | Comments |
| Oil Pressure at Low Idle | ||||
| Oil Pressure at High Idle | 262 to 359 kPa (38 to 52 psi) |
From Specifications, SENR5022, "3013 Engine for Caterpillar Built Machines", "Water Temperature Regulator" |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Basic Engine
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| Status (1) | Description | Specification | Actual | Comments | ||
| New | Rebuild | Service Limit | ||||
| Engine Performance - Test (Engine Speed) | ||||||
| No Load Low Idle | 1400 ± 25 rpm | 1400 ± 25 rpm | ||||
| No Load High Idle AEC OFF |
2560 ± 25 rpm | 2560 ± 25 rpm | ||||
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Air Inlet and Exhaust System
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| Status (1) | Description | Specification | Actual | Comments |
| Inlet Manifold Pressure - Test | - | |||
| Cylinder # 1 Exhaust Temperature (2) | ||||
| Cylinder # 2 Exhaust Temperature (2) | ||||
| Cylinder # 3 Exhaust Temperature (2) | ||||
| Cylinder # 4 Exhaust Temperature (2) | ||||
| Cylinder # 5 Exhaust Temperature (2) | ||||
| Cylinder # 6 Exhaust Temperature (2) | ||||
| Cylinder # 7 Exhaust Temperature (2) | ||||
| Cylinder # 8 Exhaust Temperature (2) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
| ( 2 ) | Compare the exhaust temperature variance at each exhaust port. |
Performance Checks
ReferenceRefer to Testing & Adjusting, RENR2846, "Performance Tests" for more detail on the following test.
Operational Checks
Travel on Level Ground - Test
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| Status (1) | Description | Specification | Actual | Comments |
|---|---|---|---|---|
| Travel Time for 25 m (82 ft) (time in seconds) (2) |
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| High Forward | 17.5 ± 2.5 | |||
| High Reverse | 17.5 ± 2.5 | |||
| Low Forward | 26.0 ± 1.5 | |||
| Low Reverse | 26.0 ± 1.5 | |||
| Travel Deviation - Check | ||||
| High Forward | 1500 mm (59 inch) |
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| High Reverse | 1500 mm (59 inch) |
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| Low Forward | 1500 mm (59 inch) |
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| Low Reverse | 1500 mm (59 inch) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
| ( 2 ) | First 5 m (16.4 ft) is preliminary. Measure travel time for remaining 20 m (65.6 ft). |
Travel on Level Ground - Test (Optional Test)
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| Status (1) | Description | Specification | Actual | Comments | |
|---|---|---|---|---|---|
| Right | Left | ||||
| High Forward (2) | 9.7 ± 1.5 | ||||
| High Reverse (2) | 9.7 ± 1.5 | ||||
| Low Forward (3) | 15.7 ± 1.5 | ||||
| Low Reverse (3) | 15.7 ± 1.5 | ||||
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
| ( 2 ) | Differential of less than 0.08 seconds between Right and Left |
| ( 3 ) | Differential of less than 0.14 seconds between Right and Left |
Machine Drift on a Slope - Check
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| Status (1) | Description | Specification | Actual | Comments |
|---|---|---|---|---|
| Machine Drift (mm (inch)) (2) | 30 mm (1.2 inch) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
| ( 2 ) | After 3 minutes |
Swing Speed and Overswing on Level Ground - Check
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| Status (1) | Description | Specification | Actual | Comments |
|---|---|---|---|---|
| Swing Speed (three revolutions) (seconds) | ||||
| Right Swing | 20 ± 2 | |||
| Left Swing | 20 ± 2 | |||
| Overswing mm (inch) (2) | ||||
| Right Swing | 190 mm (7.5 inch) |
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| Left Swing | 190 mm (7.5 inch) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
| ( 2 ) | Bucket Load 105 kg (231 lb) |
Swing Drift on a Slope - Check
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| Status (1) | Description | Specification | Actual | Comments |
|---|---|---|---|---|
| Loaded Bucket mm (inch) (3 minutes) (2) | ||||
| Right Swing | 20 mm (0.8 inch) |
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| Left Swing | 20 mm (0.8 inch) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
| ( 2 ) | Bucket Load 105 kg (231 lb) |
Cylinder Drift - Check (Loaded Bucket)
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| Status (1) | Description | Specification | Actual | Comments |
|---|---|---|---|---|
| Loaded Bucket mm (inch) (3 minutes) (2) | ||||
| Boom Cylinder | 10 mm (0.4 inch) maximum |
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| Stick Cylinder | 10 mm (0.4 inch) maximum |
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| Bucket Cylinder | 5 mm (0.2 inch) maximum |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
| ( 2 ) | 105 kg (231 lb) |
Cylinder Speed - Check
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| Status (1) | Description | Specification | Actual | Comments |
|---|---|---|---|---|
| Boom Extension | 2.5 ± 0.5 | |||
| Boom Retraction | 3.7 ± 0.5 | |||
| Stick Extension | 4.2 ± 0.5 | |||
| Stick Retraction | 2.8 ± 0.2 | |||
| Bucket Extension | 2.7 ± 0.3 | |||
| Bucket Retraction | 2.1 ± 0.2 | |||
| Boom Swing Cylinder | ||||
| Boom Extension | 8.0 ± 0.5 | |||
| Boom Retraction | 6.3 ± 0.5 | |||
| Blade Cylinder | ||||
| Blade Extension | 2.0 ± 0.2 | |||
| Blade Retraction | 1.7 ± 0.2 | |||
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Hydraulic System
ReferenceRefer to Testing & Adjusting, RENR2846, "Hydraulic Systems" for more detail on the following test.
Pilot System Pressure - Test
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| Status (1) | Description | Specification | Actual | Comments |
| Pilot System Pressure | 3100 ± 300 kPa (450 ± 44 psi) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Relief Valve (Main) - Test and Adjust
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| Status (1) | Description | Specification | Actual | Comments |
| Piston Pump 1 (Move the Boom Control Lever to the RAISE position at HIGH Idle.) | 21100 ± 500 kPa (3060 ± 75 psi) |
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| Piston Pump 2 (Move the Stick Control Lever to the OUT position at HIGH Idle.) | 21100 ± 500 kPa (3060 ± 75 psi) |
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| Gear Pump (Move the Blade Control Lever to the RAISE position at HIGH Idle.) | 17650 ± 450 kPa (2560 ± 65 psi) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Relief Valve (Line) - Test
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| Status (1) | Description | Specification | Actual | Comments |
| Boom Raise Line Relief Valve | 23750 ± 250 kPa (3445 ± 36 psi) |
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| Boom Lower Line Relief Valve | 23750 ± 250 kPa (3445 ± 36 psi) |
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| Stick Out Line Relief Valve | 23750 ± 250 kPa (3445 ± 36 psi) |
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| Stick In Line Relief Valve | 23750 ± 250 kPa (3445 ± 36 psi) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
Relief Valve (Swing) - Test
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| Status (1) | Description | Specification | Actual | Comments | |
| Swing Relief Valve (Left Swing) | 17000 to 21000 kPa (2466 to 3046 psi) |
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| Swing Relief Valve (Right Swing) | 17000 to 21000 kPa (2466 to 3046 psi) |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
S.O.S
ReferenceRefer to Operation and Maintenance Manual, SEBU7203, "Maintenance Interval Schedule" for more detail on the following S.O.S.
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| Status (1) | Description | Obtain | Comments |
| Engine Oil Sample | |||
| Engine Coolant Sample (Level I) | |||
| Engine Coolant Sample (Level II) | |||
| Hydraulic Oil Sample | |||
| Right Final Drive Oil Sample | |||
| Left Final Drive Oil Sample | |||
| Swing Drive Oil Sample |
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| ( 1 ) | N = Normal, M = Monitor, A = Action |
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