[THCM/TTC-KGP/SOP/2]

PRE – DELIVERY INSPECTION OF EX200 SUPER

TOOLING REQUIRED
Open spanners (12-13,14-15,16-17,18-19, 20-22,24-27,30-32) for pilot hoses, pressure hoses
27 mm Socket, Extension, T Handle, Ratchet for track shoe bolt tightening
19 mm Ring spanner for opening diesel tank bottom cover
8 mm Allen Key for loosening travel device level plug
Hydrometer for checking battery specific Gravity
Tray for sediment draining from fuel tank & water separator.
Cotton cloth for cleaning of grease & oil.
Polish Cloth for cylinder piston rod cleaning
Grease Gun filled with Grease for greasing pins

DOCUMENTS USED TO GENERATE REPORT

Receiving cum inspection Report format
Pre-Delivery Inspection Report format
Delivery Inspection Report format

SAFETY NOTES / TAG OUT DETAILS / UNIT SET UP

1. Follow Safety Rules always to complete the task.

2. Before starting of work put work instruction tag & remove key from machine.

3. Concern Supervisor to coordinate this procedure.

4. All precautions for working at heights must be adhered to for this task.

5. The machine should be washed down taking special care to clean the specific component area before the machine is moved to the
final work area.

6. Check all tools and test equipment are in good condition and fit for work before use.

7. After completion of work remove work instruction tag & put key in the machine.

ACTIVITY BEFORE STARTING OF WORK

1. Arrange all tools & tackle before starting of work & place these near to machine.
2. Wash the machine if possible before commencement of work.
3. Start the work from one point & end the work at same point i.e. 360-degree inspection (start the work from Bucket & end at
Bucket)
4. Perform the work as per Delivery Inspection Sheet / PDI Sheet.
5. Any abnormalities & correction should be mentioned in the sheet
Pre -DELIVERY INFORMATION REPORT

S/No. Task Reference & Remarks

Placing the machine:

1.
Make all set up and ensure all personnel have an
effective means of communication with the person
coordinating the procedure. Site supervisor to
ensure proper PPEs.
Place the machine on the firm level surface.
Release the air from hydraulic tank by air release
valve.
Hazard: Unplanned movement & oil will spray out
From damage or loose hoses
Control: Wear PPE’s & follows safety rules.

Machine serial number / Hour Meter / Date:

2.
Machine serial no. should be given outside of cabin
right side bottom.
Hour meter should be noted from cluster before
shunt down of machine along with date.
All these data should be mentioned in the check
sheet.

1 2

Bucket Inspection:
3.
Missing of tooth point.
Looseness of tooth pint & side cutter.
Check crack in plate & weld joints.
Bucket Grease nipple status.
Greasing of bucket pins if required.
Bucket Bucket
Teeth

Bucket cylinder & link Inspection:

4
Check for any damage in bucket cylinder link (1).
Check Greasing points of link& if required grease it.
External damages like scratches/scar marks on
cylinder piston (2).
Clean cylinder piston rod (if there is dust or grease)
by polish cloth.
Check for hydraulic oil seepage from rod end dust 2 1
seal
Check bucket hoses for oil damage, seepage &
leakage.
 Inspection of ARM:
5.
Check painting for any scratches.
Check for external damage.
Check for weld cracks.

Arm

Inspection for Boom & Arm cylinder:

6
Check for any damage in the cylinder & boom.
Check for any damage / dent on cylinder rod.
Check both hose of Arm cylinder for any leakage /
damage.
Inspect boom light for any damage both side.
Arm
Cylinder
Boom

Inspection of Boom Cylinder:

7
Check for external damage of both boom cylinder.
Check for scratch on cylinder rod.
Check for any damage/ leakage in both hose of boom
cylinder.
Check status of grease nipple.

Boom Boom
Cylinder Cylinder

Inspection of Front Attachment Hoses:

8
Check all hoses for external damage & Leakage.
Check steel pipe over boom for any damage or leakage.

Inspection of Track Chain & Track Guard Bolt:

9
Inspect & check bolt missing and looseness.

If Found missing replace the same.

If found looseness tighten the same.

Tools Required:
22mm socket, extension rod & T- Handle

Track
Guard
 Sediment Drain from Fuel Tank:
10
Location: Pump compartment bottom.
Place oil drain container under drain valve (1) to collect
the drained water.
Open drain valve (1) and drain water and sediment
through the drain valve.
After draining water, tighten drain valve (1).
1
Hazard: Oil will spray out from the valve.
Control: Wear PPE’s
Tools Required:
Small oil drain container (to collect drain water).

Inspection of Utility Box & Handrail:

11
Check handrail for external damage & mounting bolt
looseness (1). 1
Check utility box for external damage (2).
Check inside of utility box for availability of fuel pump.
Check utility box lock (3) for proper functioning. 2

Inspection of Fuel Tank & Hydraulic Tank:

12
Visually check the fuel (2) & Hyd. Tank (1) for any
external damage Dent or wear on the body.

1 2

Pump Compartment Door Checking:

13
Check the proper functioning of pump compartment door
& its lock (1).
Check for any damage or scratch in the door.

Hydraulic Oil Level Checking:

14
Location: Side of hydraulic oil tank near pump
Compartment.
Position During Level Check:
Arm cylinder fully retracted.
Bucket fully extended.
Lower the bucket on the ground & stop the engine.
Check oil level with level gauge (1) at the side of the
hydraulic oil tank. When the oil level is correct, it can be
seen between marks on level gauge (1).

1
 Bleed Air from Fuel System:
15
Make sure that the plug on top of the water separator and
the drain plug are closed.
Check that fuel cock on the bottom of the fuel tank is
opened.
Loosen air bleed plug of the fuel main filter. Move feed
pump up and down until no bubble comes out.
NOTE: Do not loosen plug on top of the fuel pre-filter when
bleeding air. If plug is loosened, air cannot be bled.
Tighten air bleed plug on the fuel filter.
Move feed pump up and down until its operation force
gets heavier, tighten the air bleed plug.
Start the engine. Check the fuel supply system for fuel
leaks.

Pump Compartment Hose & filter:

16
Check all hoses for leakage.
Check hose clamp & its routing, if missing replaced it.
Check all filters for looseness & leakage.
Tools:

Inspection of Counter Weight:

17
Check for any external damage.
Status of sticker.
Check looseness of mounting bolt.
Counter
Weight

Travel Device Assembly (Both Side):

18
Position travel device as shown in figure for level check.
Slowly loosen plug (1) to release air pressure.
Remove plugs (1 and 2).
When the oil level is correct, the gear oil will flow out of
the tapped hole of plug (2). Refill as necessary. 1
Wrap the thread of both plug with Teflon tape &
Reinstalled and tightened the plug.
Check both side of travel motor guard & hoses for any
damage or leakage.
2
Hazard: Pressure may be accumulated inside the device
& oil will spray-out.
Control: Remove the plug only after releasing pressure
by slowly loosening the air bleed plug two to three turns.
Tools: 8mm Allen key.
 Inspection of Air Filter:
19
Check the proper functioning of compartment door & its
lock (1).
Check for any damage or scratch on the door.
Status of sticker.
1

Inspection of Battery Compartment:

20
Battery:
Loose wings nut & remove battery cover.
If dust is over the battery, clean it.
Check battery terminals for tightness or oxidation.
Check electrolyte level & top up if level low.
Check battery specific gravity (1.24 to 1.30).
If the specific gravity is 1.23 or less, either charge or
replace the battery.
Hazard: Battery may explode when terminals
Shorted.
Control: Wear PPE’s & insulated tools
Tools: Ring / Open spanner & Hydrometer

21 Coolant Level :

Check coolant level in sub tank (1) & top up if required. 1

Air Filter Compartment & Pre-Cleaner:

22
Check filter compartment for any external damage in filter
& Pre- filter assembly.
unfasten lock on outer cover.
Take out cover & filter element.
Check filter element for external damage & cleanness.
If dust in the inner side of compartment, clean it.
Fit the filter element properly.
Fit the outer cover by fastening clamp.
Note: Do not clean the inner element, if found dusty
or damage replaced it.
 Inspection of Cabin out -side:
23
Inspect the cabin from outside for any external damage.
Check for proper functioning of door & AC fresh air filter
cover.
Check for damage in glass around cab & door bits.
Check damage in front guard cover.
Check status of wiper blade.

Diesel Filling Port & Hydraulic Tank Air Release

24
Valve:
Check diesel filling port (1) for its locking system.
2
Remove lock & check filter is available or not.
Check air bleed valve (2) operation.
Check its mounting bolt for its looseness.

Inspection of Swing Device Area and level checking:

25
Check the swing area for any leakage.
Check hydraulic hoses for tightness. Level
Clean the area around the swing device level gauge. Gauge Oil filling
Remove the level gauge (1) & check level. port
If required top- up the oil from filling port (2).

Inspection of Control Valve Area:

26
Check for any leakage.
Check hydraulic hoses for tightness.
Check for routing of hoses & its clamp.

Inspection of ROC:
27
Check for coolant level.
Check for any damage & leakages.
Radiator
 Inspection of Fan Belt:
28
Check fan belt tension by pressing the midpoint between the fan
pulley and the alternator pulley.
Apply force of approximately 98 N (10 kgf).
Standard limit 2.5 to 3mm.

Inspection of Engine:
29
Check for any leakage around engine, Engine oil filter &
Diesel filter assembly.
Check engine oil Level with the help of level gauge.
If level is low top-up through filling port.
Hazard: Engine cover may fall.
Control: Lock the engine cover properly.

Inspection of Inside Cab:

30
Put the key at ON position.
Check Right Side Console:
Check the all switch right console for proper functioning &
damage.

Check Monitor Panel:

Check proper function of Monitor panel for gauges,
indicators & hour meter.

Inspection of Wiper:
31
Check wiper for proper functioning.
Check condition of wiper blade.
Check for ant damage in wiper assembly.

Wiper

Inspection of Work light:

32
Put work light switch ON to check proper functioning of
light.

RUN ENGINE TO LUBRICATE AND CHARGE BATTERY:

33
Crank engine with starting motor for 5 to 10 seconds.
warm up and run engine at idle speed 10 minutes without
operation.
Run engine at medium speed for 20 to 30 minutes.
 Performance Checking of Machine:
34

Checking Leakage after Operation:

35
Engine oil (Cylinder head, Oil Pan, Blow By hose etc.)
Radiator & its sub tank etc.
Transmission Oil (Pump, Swing & Travel).
Hydraulic oil (All hydraulic components, all cylinders, Hydraulic tank & Oil cooler).
Fuel (Fuel Tank & fuel filter etc.).
Water (Washer Tank).
All hoses & piping.
Grease piping.

Changing Oil:
36
Oil Type Replacement Brand of Oil Grade
Interval

Engine Oil RIMULA T4 15W40 CI4

Every 6 months
Engine Oil Filter

Coolant
Every 12 months
Hydraulic Oil 46 U

Hydraulic Filter

Fuel Filter

Pilot Filter

Swing device gear oil HP 90

Every 12 months
Travel device gear oil

Battery Fluid
 Comments & Unsatisfactory Photo:
37
During any observation or defective / missing item, write detailed comments & take photo of the defective parts with detailed report in
FIR.
How to Take Photo:
First Step: - Take photo of complete machine.
Second Step: -Take photo of closer view of defective part.
Third Step: - Take photo of defective parts in magnifying view.