TA1 Inspection Training For Hydraulic Excavators - Kamp

Caterpillar Basic Preventive Maintenance
Hydraulic Excavator Walk Around Inspection (TA1)
Walk-Around Inspections
• Machine Inspection Benefits
• Machine Inspection
Preparation
• Download Fault Codes
• Lower-Level Inspections
• Middle-Level Inspections
• Upper-Level Inspections
• Implement/Attachment
Inspections
Condition Monitoring Boot Camp - Dallas - January 2012

Inspection Benefits
• Minimizes downtime through
scheduled maintenance
• Identifies potential problems
• Uncovers overlooked
problems
• Enables efficient scheduling
of maintenance and repairs
• Lowers owning and operating
costs
Condition Monitoring Boot Camp - Edwards - September 2011

Inspection Benefits
Breakdown of Parts & Service Sales Revenue achieved
through Condition Monitoring Elements.

New TA1 & TA2 Inspection Forms

TA1 Inspection Forms
TA2 Inspection Forms

• New TA1 & TA2 Inspection Forms for 19 Machine Families
• New TA1 & TA2 Inspection Forms for 7 Engine Applications

Inspection Forms
TA2
TA1
• RED, YELLOW, GREEN Format
• Sequenced steps for improved efficiency
Inspection Forms are located at
DEALER.CAT.COM
•Section Definition
•Processes – Drive Standard Work
Describes the ordered steps, by role, and then links to other related processes and resources
(end-to-end) to drive efficiency.
•Practices – Drive Standard Work
Documents the methods and techniques used to remedy specific problems and will evolve
through continuous improvement.
•People – Develop People
Utilizes DLMS and other sources of training methods and materials for role based learning.
•Tools
•Reference Documents

TA1 & TA2 Inspection Forms
• Inspection Forms are located at the following web address:

https://dealer.cat.com/cda/layout?m=437395&x=7

Forms can also be downloaded from SIS


Service Marketing Information


Service Marketing Information
• Extract TA1 & TA2 Inspections Master Forms.zip

Machine Inspection Preparation

• Be sure the area is free of personnel –
make sure no one is underneath the
machine, around the machine, or on
the machine.
• Turn the key to the ON position to

check fluid levels using the monitor. If
fluid levels cannot be checked using
the monitor, manually check the
engine oil, hydraulic oil, and coolant
levels. If necessary, add engine oil,
hydraulic oil, or coolant to reach
minimum level.
• Park the machine in the standard

service position.
Download Machine Fault Codes
Download machine fault

codes using either of these
two methods:
• Electronic Technician (ET)
• Machine monitor

Observe Engine Exhaust Colors

• Start the machine and
watch exhaust colors
• White smoke after initial
startup could indicate coolant
in engine cylinder.
• Blue smoke during startup
indicates oil in engine
cylinder.
• Continuous black smoke
indicates improper air/fuel
mixture.
• Continuous gray smoke
indicates a fuel timing
problem.
Listen for Unusual Noises

• Excessive noise coming from
hydraulic pump could indicate:
– Pump cavitation
– A loose or failed bearing
• Excessive noise coming from
engine compartment could
indicate:
– Fuel injector damage
– Engine bearing damage
– Valve train damage

Wiring Harness Inspection Guidelines

Rubbing on
Sharp Edges
Check for
Rubbing
Hose on Bolt Head •Tubes, hoses, and wiring
harnesses rubbing against:
Rubbing Hose – One another
on Hose
Rubbing
Hose on Harness
– Sharp corners
– Bolt heads
•Tubes, hoses, and wiring
Rubbing
harness not properly
Hose on Tubes
secured:
– Missing clips and wire ties
Unsecured – P-clips not attached
P-Clip

Harness Connector Inspection Guidelines Rubbing on

Sharp Edges
Check for connectors:
•Not properly secured in
Rubbing on
place
•Rubbing against machine
Sharp Edges
frame
•Rubbing against sharp
Rubbing against
Other Surfaces edges
Rubbing against
Other Surfaces
Improperly Secured
Connector
Results of Improperly
Secured Connector

Linkage Pin Inspection Guidelines

Pin Flag Check for:
• Loose or broken flange mounting bolt
• Elongated bolt hole in flange
Pin Retainer Bolt
(hole is located behind pin retaining
bolt)
• Loose or missing pin retainer bolts
• Irregular-shaped pin bores
Retaining Bolt
Check for
Irregular-Shaped
Pin Bores

Hydraulic Cylinder Inspection Guidelines

Check for:
• Oil leaks indicated by dirt or oil
Damaged
Cylinder Rod
buildup around the cylinder lip seal
• Oil leaks at hose connections
Leaking Cylinder Head • Damage to cylinder rods
Lip Seal
• Damage or wear to linkage pins
Note: Refer to “Linkage
Pin Inspection Guidelines” Cylinder
for inspection procedure. Connection
Cylinder
Connection

Lower-Level Inspections
• Final drives and sprockets
• Travel motors and brake valves
• Track adjusters
• Carrier rollers
• Track rollers
• Front idlers
• Track guides
• Track shoes
Note: Prior to machine inspection, • Track links, pins, and bushings
park the machine in the standard
service position. • Track roller frames and carbody

Final Drive and Sprocket Inspection

Fill Plug • Check oil level in final drives
– If equipped, check the magnetic plug for
metal particles
– If the oil level is low, check the following
Cover
areas for leaks:
Drain Plug • Sealing surface between the cover and the ring
gear
• Sealing surface between the ring gear and the
Ring Gear housing
• Duo-cone seal located behind the sprocket
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
Housing

Travel Motor & Brake Valve Inspection

Check for:
• Oil leakage along the
bottom surface of travel
motor housing
– If oil is visible in this area,
Oil Leakage remove the cover and
inspect the travel motor,
brake valve, and oil lines
for leakage

Track Adjuster Inspection

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
Piston Lip Seal
area indicates piston lip seal or
piston rod may be worn or damaged
• Check track adjuster grease fitting
for damage
Piston

Track Roller Inspection

Check for:
• Oil leakage from the following
Check for
Surface
areas:
Shaft
Wear
– From the duo-cone seals
located on the front and back
side of the track roller
– At each end of the track roller
shaft; leakage in this area
Duo-Cone Seal Duo-Cone Seal indicates the O-ring seal
Location
Location located on the track roller shaft
may worn or damaged
• Excessive wear on the surface
where the track link rides on the
track roller
Track Shoe Inspection

Check for:
Track Bolts • Damaged, missing, or
loose track bolts
• Damaged or worn
track shoes
Track Shoe

Middle-Level Inspections
• Cab Exterior • Radiator, Oil Cooler,
• Cab Interior Condenser, & Aftercooler
• Steps and Handrails • Lower Radiator & Oil
• Work Lights Cooler Hose
• Air Cleaner • Counterweight
• Wiring Harnesses • Engine Oil Pan
• Wiring Harness • Hydraulic Pump
Connectors Compartment
• Battery and Battery • Swing Drive
Cables
Cab Exterior Inspection

Check for:
• Bent or damaged cab structure
• Cracked or broken glass
• Damaged or missing mirrors
• Worn or broken windshield,
wiper arm, or wiper blade

Cab Interior Inspection

Check for:
• Excessive dirt in cab air filter
• Proper function of 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
Steps & Handrails Inspection

Handrails
Steps
Ensure that steps and
handrails are in place and
check for:
Mounting
Bolts •Damaged, missing, or loose
bolts
•Damage to steps or handrails
Steps
•Excessive dirt or debris

Work Light Inspection

Check for:
• Proper operation
• Cracked or broken lenses
• Damaged harnesses or
electrical connectors
• Loose or damaged
mounting brackets

Battery and Battery Cable Inspection

Check:
•Battery posts and cables
for corrosion or damage
•Battery hold down for
Battery
Hold-Down proper function and
tightness
Battery Posts
And Cables

Inspect Hydraulic Pump Compartment

Check for:
•Leaks around hose connection
points
•Rubbing, damaged, or worn
hoses
•Loose or damaged hose clamps
on main pump suction lines
Note: Check for rubbing, damaged,

Suction Line
Hose Clamps
or worn wiring harnesses or
connectors.

Upper-Level Inspections
• Hood and Platform • Radiator/Oil Cooler Screen
• Exhaust Manifold • Water Pump
• Turbocharger • Radiator Cap
• Cylinder Head and Valve • Fuel Priming Pump, Fuel
Cover Lines, and Fuel Injection
• Engine Mounts Pump
• Belts, Pulleys, and • Engine Wiring Harness
Compressor Clutch • Swing Drive Compartment
• Fan Guard and Fan • Swing Drive
• Upper Radiator, Air Inlet, • Main Hydraulic Control Valve
Oil Cooler & Aftercooler Lines
Turbocharger Inspection
Check for:
•Black soot around the areas
Turbocharger
where the turbocharger bolts to
the to the exhaust manifold or to
the exhaust pipe, which would
indicate:
Check Sealing
Surfaces
– Loose connection at the joint
Hose Clamps – Loose or broken mounting bolts
•Oil leakage around the
turbocharger oil line
•Loose or damaged hose clamp on
air inlet tube
Cylinder Head & Valve Cover Inspection

Check for:
• Oil and dust buildup around
the valve cover sealing
surface, which would indicate:
Valve Cover – Loose connection at the joint
– Damaged gasket or seal
Protective • Fuel leaks around and below
Cover
the protective cover located
above the fuel lines. If fuel
leaks are present on the
intake manifold, remove the
guard and inspect fuel lines
for leaks.
Belts, Pulleys, and Compressor Inspection
Alternator/Water
Pump Belt Check for:
• Worn, cracked, or broken
Alternator Belt Tensioner belts
• Proper belt tension
Compressor Clutch
• Oil leaks around air
Air Conditioning
Compressor Belt conditioning compressor
clutch

Inspect Upper Radiator, Air Inlet,

Oil Cooler, and Aftercooler Lines
Check for:
• Rubbing, cracked, or damaged
Oil Cooler Hose
hoses
Upper Radiator • Loose or damaged hose clamps
Hose
Air Inlet Hose
Turbocharger Air
Inlet Hose Aftercooler Hose
Turbocharger
Air Outlet hose

Swing Drive Inspection

• Check 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
Swing Drive • Joint where the dipstick tube
Housing Cover
Dipstick Tube
connects to the swing drive housing
• If no leakage is found in these areas,
leakage may be caused from a worn
Swing Drive
pinion shaft or bottom cover seal. To
Ring Gear service these seals, the swing drive
must be removed.

Implement/Attachment Inspections
• Area Around Boom • Bucket Cylinder
Cylinders and Swivel • Bucket Linkage
• Lower Boom Area • Bucket Wear Plates
• Boom Cylinder • Side Cutters
• Area Where Boom • Bucket Tips and Adapters
Attaches to Stick
• Stick Cylinder
Note: Prior to implement inspections, extend the stick, open the

bucket, and lower the boom.

Inspect Lower Boom Area

Check for:
• Leaks around hose connections
• Rubbing, damaged, or worn hoses
• Damaged or leaking grease lines
• Inspect boom foot pin
Note: Refer to “Linkage Pin Inspection
Guidelines” for inspection procedure.
Boom
Foot Pin
Hoses Rubbing
on Bolt Head

Bucket Linkage Inspection

(Refer to “Linkage Pin Inspection Guidelines” for inspection procedure.)
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

Bucket Wear Plate Inspection
Check for:
Wear Plates
• Excessive wear

Tip & Adapter Inspection
Check for:
• Excessive wear on the
bucket tip
Bucket Tip Adapters
• Damage to the bucket tip
adapter
• Damage or missing
Bucket Tips
retainer pins

TA1 Inspection Training For Hydraulic Excavators - Kamp

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Caterpillar Basic Preventive Maintenance

Hydraulic Excavator Walk Around Inspection (TA1)

Condition Monitoring Boot Camp - Dallas - January 2012

Condition Monitoring Boot Camp - Edwards - September 2011

Condition Monitoring Boot Camp - Edwards - September 2011

New TA1 & TA2 Inspection Forms

TA2 Inspection Forms

Condition Monitoring Boot Camp - Edwards - September 2011

Condition Monitoring Boot Camp - Edwards - September 2011

TA1 & TA2 Inspection Forms

• Inspection Forms are located at the following web address:

TA1 & TA2 Inspection Forms

Condition Monitoring Boot Camp - Edwards - September 2011

TA1 & TA2 Inspection Forms

Condition Monitoring Boot Camp - Edwards - September 2011

TA1 & TA2 Inspection Forms

• Extract TA1 & TA2 Inspections Master Forms.zip

Machine Inspection Preparation

• Turn the key to the ON position to

• Park the machine in the standard

Download Machine Fault Codes

Download machine fault

Condition Monitoring Boot Camp - Edwards - September 2011

Observe Engine Exhaust Colors

Listen for Unusual Noises

Condition Monitoring Boot Camp - Edwards - September 2011

Wiring Harness Inspection Guidelines

Condition Monitoring Boot Camp - Edwards - September 2011

Harness Connector Inspection Guidelines Rubbing on

Condition Monitoring Boot Camp - Edwards - September 2011

Linkage Pin Inspection Guidelines

Condition Monitoring Boot Camp - Edwards - September 2011

Hydraulic Cylinder Inspection Guidelines

Condition Monitoring Boot Camp - Edwards - September 2011

Condition Monitoring Boot Camp - Edwards - September 2011

Final Drive and Sprocket Inspection

Sprocket • Inspect the sprockets

Condition Monitoring Boot Camp - Edwards - September 2011

Travel Motor & Brake Valve Inspection

Condition Monitoring Boot Camp - Edwards - September 2011

Track Adjuster Inspection

Condition Monitoring Boot Camp - Edwards - September 2011

Track Roller Inspection

Track Shoe Inspection

Condition Monitoring Boot Camp - Edwards - September 2011

Cab Exterior Inspection

Condition Monitoring Boot Camp - Edwards - September 2011

Cab Interior Inspection

Steps & Handrails Inspection

Condition Monitoring Boot Camp - Edwards - September 2011

Work Light Inspection

Condition Monitoring Boot Camp - Edwards - September 2011

Battery and Battery Cable Inspection

Condition Monitoring Boot Camp - Edwards - September 2011

Inspect Hydraulic Pump Compartment

Note: Check for rubbing, damaged,

Condition Monitoring Boot Camp - Edwards - September 2011

Cylinder Head & Valve Cover Inspection

Belts, Pulleys, and Compressor Inspection

Condition Monitoring Boot Camp - Edwards - September 2011

Inspect Upper Radiator, Air Inlet,

Condition Monitoring Boot Camp - Edwards - September 2011

Swing Drive Inspection