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.

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:   
(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.

  1. Click format to print.

  2. Save the document as an HTML format.

  3. Open the document with Microsoft Word.

Visual Inspection

1.0 Prepare Generator Set Inspection

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

2.0 Lower-Level Inspection

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

3.0 Upper-Level Inspection

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

4.0 Generator Inspection

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

5.0 Site Conditions

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

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