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

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

Usage:

Industrial Engine with Turbochargers: 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
Application:	Power/RPM:	Date :
Model:	Inspector:	SMU:
Engine S/N:	Work Order #	Unit Location:
Arrangement #:
Note: Review Engine & S.O.S. History and check for Active Service Letters prior to inspection.
Status of the Machine⁽¹⁾
The status recommendation of your Industrial Engine is:

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

Creating an Electronic Copy

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Visual Inspection

1.0 Prepare Industrial Engine for Inspection

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Table 2
Sl.No.	Status⁽¹⁾	Description		Comments
1.1		Prepare the Industrial Engine for the inspection
1.2		Download fault codes - ECM data
			Logged fault codes - ECM data
			Active fault codes - ECM data
1.3		Observe engine exhaust colors
1.4		Listen for unusual noises (engine & driven equipment)

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

2.0 Basic Engine - Inspection

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Table 3
Sl.No.	Status⁽¹⁾	Description	Comments
2.1		Check engine oil level
2.2		Engine oil pan
2.3		Crankcase breathers and piping
2.4		Oil Filters, filter bases, cooler, and lines
2.5		Engine mounts, isolators, supports, and rails
2.6		Engine/driven equipment coupling
2.7		Flywheel housing
2.8		Starter motors (Air or Electric)
2.9		Air starter lubricator
2.10		Prelube pump (if equipped)
2.11		Front housing and covers
2.12		Crankshaft vibration damper
2.13		Cylinder heads
2.14		Rocker boxes and valve covers
2.15		Injectors
2.16		Pulleys, belts (alternator and accessory)
2.17		Inspect gauge panel
2.18		Inspect engine wiring
2.19		Inspect battery terminals, connections, and cables
2.20		Inspect guards on driven equipment (if equipped)

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

3.0 Cooling System - Inspection

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Table 4
Sl.No.	Status⁽¹⁾	Description	Comments
3.1		Check coolant level
3.2		Radiator cap
3.3		Pressure relief valve
3.4		Radiator cores
3.5		Water pumps
3.6		Water hoses
3.7		Belt guards
3.8		Belt tensioner
3.9		Fan drive
3.10		Fan belt
3.11		Screen guard

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

4.0 Air Inlet and Exhaust System Inspection

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Table 5
Sl.No.	Status⁽¹⁾	Description	Comments
4.1		Air cleaner elements and housings
4.2		Air restriction indicator
4.3		Air Inlet and exhaust lines
4.4		Exhaust manifolds
4.5		Muffler, exhaust stack, and exhaust flexible coupling
4.6		Turbochargers
4.7		Wastegate
4.8		Aftercooler cores
4.9		Aftercooler housings

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

5.0 Fuel System Inspection

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Table 6
Sl.No.	Status⁽¹⁾	Description	Comments
5.1		Fuel supply/return lines
5.2		Fuel priming pump
5.3		Fuel injection lines and retainers
5.4		Fuel/water separator
5.5		Fuel filters
5.6		Fuel day tank

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

6.0 Site Conditions

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Table 7
Sl.No.	Status⁽¹⁾	Description	Comments
6.1		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)
6.2		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)
6.3		Haul Road Grade
		NORMAL: Flat
		MONITOR: Mild
		ACTION: Steep
6.4		Haul Road Condition
		NORMAL: Positive Banking, Gradual Turns, Good Erosion Control
		ACTION: Negative Banking, Sharp Turns, Poor Erosion Control
6.5		Humidity
		NORMAL: Below 25%
		MONITOR: 25 to 60%
		ACTION: Above 60%
6.6		Air Quality
		NORMAL: No Dust
		MONITOR: Light Dust
		ACTION: Heavy Dust
6.7		Underfoot Condition
		NORMAL: Dry Flat Surface
		MONITOR: Moderate Grades, Mixture of Muddy / Dry Surfaces
		ACTION: Steep Grades, Muddy, Snow, Ice
6.8		Machine Utilization
		NORMAL: 0 to 10 Hours
		ACTION: Above 10 hours
6.9		Equipment Role
		NORMAL: Utility
		MONITOR: Support
		ACTION: Production
6.10		Working Material
		NORMAL: Uncompacted, Low Abrasion
		MONITOR: Moderately Compacted, Moderate Abrasion
		ACTION: High Abrasion, Compacted, Dense
6.11		Maintenance Practices
		NORMAL: Excellent
		MONITOR: Good
		ACTION: Poor
6.12		Primary Industries

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

Performance Inspection

Engine Performance Checks

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Table 8
Status⁽¹⁾	Description	Specification	Actual		Comments
Status⁽¹⁾	Description	Specification	Maximum	Minimum	Comments
	Engine Oil Pressure - Record
	Engine Fuel Pressure - Record
	Jacket Water Outlet Temperature- Record
	Aftercooler Outlet Temperature- Record
	Battery Voltage
	Engine Stopped
	Low Idle
	High Idle
	Check Battery Electrolyte Level
	Air inlet Heater Test (if equipped)
	Starter Draw Test
	Exhaust Temperature - Record (Measure at Each Cylinder)
	Cylinder 1
	Cylinder 2
	Cylinder 3
	Cylinder 4
	Cylinder 5
	Cylinder 6
	Cylinder 7
	Cylinder 8
	Cylinder 9
	Cylinder 10
	Cylinder 11
	Cylinder 12
	Cylinder 13
	Cylinder 14
	Cylinder 15
	Cylinder 16
	Cylinder 17
	Cylinder 18
	Cylinder 19
	Cylinder 20
	Exhaust Temperature - Test (Measure at Exhaust Stack)
	LH Cylinder
	RH Cylinder