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Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Safety Section
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.
Dispose of all fluids according to local regulations and mandates. |
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Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.
Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Personal injury or death can result from improperly checking for a leak.
Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. |
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| Illustration 1 | g00104545 |
Prevent the machine from movement. Park the machine on a level surface.
Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.
This inspection form is intended to assist with identification and prioritization of failure modes associated with hose assemblies and to increase your ability to identify and proactively resolve issues in order to minimize fluid loss, machine downtime and avoid environmental impact.
Various site conditions, the environment and machine age should always be considered when inspecting hose assemblies.
When performing a machine walk-around, always follow local safety guidelines and wear the appropriate PPE. Prior to inspection, turn off equipment power and release pressure from the accumulators along with the system pressure. Make sure equipment is in a safe or neutral position, retract all cylinders, drop the load, and allow enough time for cool down. Chock tires as necessary. NEVER touch a hydraulic hose that is under pressure.
Replacement Indicator Levels
When inspecting hose assemblies, the recommended Replacement Indicator Levels noted below should be considered. For detail and replacement recommendations, please reference the following pages.
Replacement indicator 1
Hose assembly is visibly damaged and risk of failure is high.
Replacement indicator 2
Hose assembly is showing early signs of fatigue or wear and risk of failure is low.
Note: Where possible take photos to highlight areas of concern and attach to report.
Replacement Indicator 1 (Major Risk)
Hose is visibly damaged and may consist of the following:
- Cover has worn through or has been damaged with exposure of the reinforcement layer.
- Hose assembly is flattened, kinked or twisted.
- Hose assembly is hard and lacks flexibility.
- Hose cover is cracked or brittle.
- Hose is actively leaking fluid.
Hose replacement is recommended immediately
Replace hose assembly urgently to ensure safety and minimize potential fluid loss/ contamination, machine downtime and negative environmental impact.
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| Illustration 2 | g06052914 |
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| Illustration 3 | g06052931 |
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| Illustration 4 | g06052934 |
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| Illustration 5 | g06052939 |
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| Illustration 7 | g06052949 |
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| Illustration 8 | g06052951 |
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| Illustration 9 | g06052952 |
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| Illustration 10 | g06052970 |
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| Illustration 11 | g06052974 |
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| Illustration 12 | g06052979 |
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| Illustration 13 | g06052982 |
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| Illustration 14 | g06052985 |
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| Illustration 15 | g06052988 |
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| Illustration 16 | g06052995 |
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| Illustration 17 | g06053003 |
Replacement Indicator 2 (Minor Risk)
Hose is showing early signs of fatigue, wear or where preventive maintenance would prolong life and may consist of the following:
- Cover shows signs of rubbing. Reinforcement is not exposed.
- Leaking connection points.
- Missing clamps, incorrect routing.
- Cover has minor cuts or cracks. Reinforcement is not exposed. Hose is still flexible.
- Hose assembly is weeping fluid (e.g. through cover, around clamps, at connection points, etc.,).
- Cover is blistered.
- Fittings are corroded.
Preventive maintenance is recommended as soon as possible
Protect hose with suitable guarding, re-route as needed, replace O-rings, clamps etc. Inspect before every shift to ensure safety and minimize potential fluid loss/contamination, machine downtime and negative environmental impact.
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| Illustration 18 | g06053012 |
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| Illustration 19 | g06053014 |
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| Illustration 20 | g06053021 |
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| Illustration 21 | g06053025 |
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| Illustration 22 | g06053032 |
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| Illustration 23 | g06053035 |
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| Illustration 24 | g06053036 |
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| Illustration 25 | g06053039 |
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| Illustration 26 | g06053042 |
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| Illustration 27 | g06053044 |
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| Illustration 28 | g06053046 |
List hoses below that need attention. Rate each hose based on severity / impact to safety, machine operation and environmental impact.
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Table 1
| Hose Assembly Part Number |
Group Number or Location |
Rating (Level) |
Comments (Recommended Actions) |
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Table 2
| Machine Model: |
Date: |
| Machine ID: |
Machine Serial #: |
| Location: |
Service Meter: |
| Site Conditions: |
Inspector: |
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