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

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

Usage:

Generator Set: G3520E (S/N: GZG1-UP; GZH1-UP)

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 Machine & S.O.S. History and check for Active Service Letters prior to inspection.
Status of the Machine⁽¹⁾
The status recommendation of your Gas Engine Generator Set is:

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

Creating an Electronic Copy

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Visual Inspection

1.0 Prepare Gas Engine Generator Set for Inspection

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Table 2
Sl.No.	Status⁽¹⁾	Description		Comments
1.1		Prepare the Gas Engine Generator Set for the inspection
1.2		Download fault codes - ECM data
			Logged fault codes - ECM data
			Active fault codes - ECM data
			Record ECM type and serial number
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		Oil level regulator (if equipped)
2.6		Engine mounts, isolators, supports, and rails
2.7		Engine/driven equipment coupling
2.8		Flywheel housing
2.9		Starter motors (Air or Electric)
2.10		Air starter lubricator (if equipped)
2.11		Prelube pump (if equipped)
2.12		Front housing and covers
2.13		Crankshaft vibration damper
2.14		Cylinder heads
2.15		Rocker boxes and valve covers
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)
2.21		Record oil type being used

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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 - Check for Debris
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
3.12		Jacket water heater (if equipped)

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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		Air Inlet shutoff
4.5		Exhaust manifolds
4.6		Muffler, exhaust stack, and exhaust flexible coupling
4.7		Turbochargers
4.8		Wastegates
4.9		Aftercooler cores
4.10		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		Throttle & Actuator Linkage
5.2		Gas Regulator
5.3		Gas Filter
5.4		Carburetors
5.5		Gas Shut-off valve
5.6		Gas Lines

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

6.0 Generator Inspection

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Table 7
Sl.No.	Status⁽¹⁾	Description	Comments
6.1		Generator
6.2		Generator set vibration isolators
6.3		Generator coupling guard
6.4		Generator coupling
6.5		Generator leads

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

7.0 Site Conditions

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Table 8
Sl.No.	Status⁽¹⁾	Description	Comments
7.1		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)
7.2		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)
7.3		Haul Road Grade
		NORMAL: Flat
		MONITOR: Mild
		ACTION: Steep
7.4		Haul Road Condition
		NORMAL: Positive Banking, Gradual Turns, Good Erosion Control
		ACTION: Negative Banking, Sharp Turns, Poor Erosion Control
7.5		Humidity
		NORMAL: Below 25%
		MONITOR: 25 to 60%
		ACTION: Above 60%
7.6		Air Quality
		NORMAL: No Dust
		MONITOR: Light Dust
		ACTION: Heavy Dust
7.7		Underfoot Condition
		NORMAL: Dry Flat Surface
		MONITOR: Moderate Grades, Mixture of Muddy / Dry Surfaces
		ACTION: Steep Grades, Muddy, Snow, Ice
7.8		Machine Utilization
		NORMAL: 0 to 10 Hours
		ACTION: Above 10 hours
7.9		Equipment Role
		NORMAL: Utility
		MONITOR: Support
		ACTION: Production
7.10		Working Material
		NORMAL: Uncompacted, Low Abrasion
		MONITOR: Moderately Compacted, Moderate Abrasion
		ACTION: High Abrasion, Compacted, Dense
7.11		Maintenance Practices
		NORMAL: Excellent
		MONITOR: Good
		ACTION: Poor
7.12		Primary Industries