Technical Analysis 1 (TA1) Visual Inspection for Generator Sets {0372, 1000, 7000, 753S, 7565} Caterpillar

Technical Analysis 1 (TA1) Visual Inspection for Generator Sets {0372, 1000, 7000, 753S, 7565}

Usage:

D386 15B

Generator Set: All

Introduction

Inspections are the most basic form of condition monitoring. They 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 before problems occur.

Note: Before adjusting product settings to comply with listed baseline TA1 values, consult SIS for the latest specification values.

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Table 1
Serial Number:	Inspector:	Temperature:
Model:	Work Order:	Time:
Engine S/N:	SMU:	Date:
Manufacture:		Unit Location:
Note: Review Equipment & S.O.S. History and check for Active Service Letters prior to inspection.
Status of the Generator Set⁽¹⁾
The status recommendation of your Generator Set is:

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⁽¹⁾	N = Normal, D = Down Generator, M = Monitor/Needs Attention

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.

Visual Inspection

1.0 Prepare Generator Set Inspection

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Table 2
Sl.No.	Status⁽¹⁾	Description	Comments
1.1		Prepare the Generator Set for the inspection
1.2		Perform walk-around inspection
1.3		Download fault codes
1.4		Observe engine exhaust colors
1.5		Listen for unusual noises (engine & driven equipment)

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⁽¹⁾	N = Normal, M = Monitor, A = Action, Blank = Not Applicable

2.0 Lower-Level Inspection

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Table 3
Sl.No.	Status⁽¹⁾	Description	Comments
2.1		Mounts, Isolators, supports & Rails
2.2		Engine Oil Pan
2.3		Crankshaft Vibration Damper
2.4		Alternator, Pulleys, Belts & Tensioner
2.5		Water Pumps
2.6		Oil Filters, Filter Bases, Cooler & Lines
2.7		Fuel Filters, Fuel Lines, Pumps & Filter Bases
2.8		Engine Block
2.9		Engine Oil Level - Check
2.10		Starter Motors
2.11		Jacket Water heater
2.12		Inspect Battery Cables and Battery Connections
2.13		Engine/Driven Equipment Coupling
2.14		Fuel Day Tank
2.15		Fuel Water Separator - Check
2.16		Prelube Pump
2.17		Speed Sensors

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⁽¹⁾	N = Normal, M = Monitor, A = Action, Blank = Not Applicable

3.0 Upper-Level Inspection

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Table 4
Sl.No.	Status⁽¹⁾	Description	Comments
3.1		Air Cleaners & Pre-cleaners
3.2		Air Cleaners Service Indicator
3.3		Turbochargers
3.4		Intake Manifold, Aftercooler, JWAC/SCAC air cooler
3.5		Exhaust Manifolds
3.6		Flexible Exhaust Coupling
3.7		Cylinder Heads & Valve Covers
3.8		Cylinder Head Grounding Stud
3.9		Cooling Fan, Fan Guard & Shroud
3.10		Upper & Lower Radiator Lines, Boost Air Lines & Aftercooler Lines
3.11		Radiator Core - Check for Debris
3.12		Fuel Cooler Core - Check for Debris
3.13		Coolant Level - Check
3.14		Radiator Cap

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⁽¹⁾	N = Normal, M = Monitor, A = Action, Blank = Not Applicable

4.0 Generator Inspection

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Table 5
Sl.No.	Status⁽¹⁾	Description	Comments
4.1		Generator
4.2		Generator Set Vibration Isolators
4.3		Generator Coupling Guard
4.4		Generator Coupling
4.5		Generator Leads

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⁽¹⁾	N = Normal, M = Monitor, A = Action, Blank = Not Applicable

5.0 Site Conditions

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Table 6
Sl.No.	Status⁽¹⁾	Description	Comments
5.1		Ambient Temperature
		NORMAL: −18 to 32°C (0 to 90°F)
		MONITOR: 32 to 46°C (90 to 115°F) or −18° to -29°C (0 to -20°F)
		ACTION: Above 46° C (115° F) or Below −29° C (−20° F)
5.2		Altitude
		NORMAL: 0 to 1524 m (0 to 5000 ft)
		MONITOR: 1524 to 3048 m (5000 to 10000 ft)
		ACTION: Above 3048 m (10000 ft)
5.3		Haul Road Grade
		NORMAL: Flat
		MONITOR: Mild
		ACTION: Steep
5.4		Haul Road Condition
		NORMAL: Positive Banking, Gradual Turns, Good Erosion Control
		ACTION: Negative Banking, Sharp Turns, Poor Erosion Control
5.5		Humidity
		NORMAL: Below 25%
		MONITOR: 25 to 60%
		ACTION: Above 60%
5.6		Air Quality
		NORMAL: No Dust
		MONITOR: Light Dust
		ACTION: Heavy Dust
5.7		Underfoot Condition
		NORMAL: Dry Flat Surface
		MONITOR: Moderate Grades, Mixture of Muddy/Dry Surfaces
		ACTION: Steep Grades, Muddy, Snow, Ice
5.8		Machine Utilization
		NORMAL: 0 to 10 Hours
		ACTION: Above 10 hours
5.9		Equipment Role
		NORMAL: Utility
		MONITOR: Support
		ACTION: Production
5.10		Working Material
		NORMAL: Uncompacted, Low Abrasion
		MONITOR: Moderately Compacted, Moderate Abrasion
		ACTION: High Abrasion, Compacted, Dense
5.11		Maintenance Practices
		NORMAL: Excellent
		MONITOR: Good
		ACTION: Poor
5.12		Primary Industries