TA-2 Visual & Technical Inspection for Generator Sets

SMCS - Job Code - 540 Component Code - 753T

Cat Dealer Customer

Address Address
Contact Contact

Serial Number : Inspector : Temperature :

Model : Work Order : Time :
Engine S/N: SMU: Date :
Manufacturer : Unit Location:

Note: Review Equipment & S·O·S History and check for Active Service Letters prior to inspection.

Status of the Generator Set

Normal
The status recommendation of your Generator Set is:
 Visual Inspection for Generator Set
Status assessment ü– Normal M – Monitor A – Action Blank – Not Applicable

1. Prepare Generator Set Inspection

# Status 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)

1.6

1.7

1.8

Item No. Additional Comment

 2. Lower-Level Inspection
# Status 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 Pump(s)

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 Motor(s)

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 Sensor(s)

2.18

2.19

2.20

Item No. Additional Comment

 3. Upper Level Inspection
# Status Description Comments
3.1 Air Cleaner(s) & Pre-cleaner(s)

3.2 Air Cleaner(s) Service Indicator

3.3 Turbocharger(s)

3.4 Intake Manifold, Aftercooler, JWAC/SCAC air cooler

3.5 Exhaust Manifold(s)

3.6 Flexible Exhaust Coupling

3.7 Cylinder Head(s) & Valve Cover(s)

3.8 Cylinder Head Grounding Stud

3.9 Cooling Fan, Fan Guard & Shroud

Upper & Lower Radiator Lines, Boost Air Lines &
3.10
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

3.15

3.16

3.17

Item No. Additional Comment

 4. Generator Inspection
# Status Description Comments
4.1 Generator

4.2 Generator Set Vibration Isolators

4.3 Generator Coupling Guard

4.4 Generator Coupling

4.5 Generator Leads

4.6

4.7

4.8

Item No. Additional Comment

6. Site Conditions
# Status Description
5.1 Ambient Temperature

NORMAL: -18° to 32°C (0° to 90°F)

MONITOR: 32° to 46°C or -18° to -29°C (90° to 115°F or 0° to -20°F)

ACTION: Above 46°C or Below -29°C
(Above 115° or Below -20°F)
5.2 Altitude

NORMAL: 0 to 1524 m (0 to 5000 ft)

MONITOR: 1524 to 3048 m (5000 to 10,000 ft)

ACTION: Above 3048 m (Above 10,000 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

5.13

5.14

5.15

Item No. Additional Comments

Other Remarks
 Technical Inspection for Generator Set
Status assessment ü- Normal M - Monitor A - Action Blank – Not Applicable

1. Engine
1.1 Cooling System
# Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.1.1 Radiator Pressure Relief (Radiator Cap)

1.1.2 1.1.2 Test Engine Coolant

Check Freezing Point of Engine Coolant

Test Engine Coolant Conditioner

1.1.3 Check Fan Drive Belt Tension

1.1.4 Jacket Water Outlet Temperature

1.1.5 Aftercooler Water Outlet Temperature

1.1.6 Jacket Water Inlet Temperature from Cooling System

1.1.7 Oil Cooler Water Outlet Temperature

1.1.8 Jacket Water Heater - Check

1.2 Fuel System
# *Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.2.1 1.2.1 Engine Speed - Check

Low Idle - no load

High Idle - no load

1.2.2 1.2.2 Fuel System Pressure - Test

Fuel Pressure at Low Idle

Fuel Pressure at High Idle

1.2.3 Fuel Filter Differential Pressure - Test

1.3 Lubrication System
# *Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.3.1 1.3.1 Engine Oil Pressure - Test

Oil Pressure at Low Idle

Oil Pressure at High Idle

1.4 Basic Engine
# *Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.4.1 Cylinder Cutout Test

1.4.2 Engine Crankcase Pressure (Blowby) - Test

1.4.3 Engine Crankcase Pressure - Test

1.5 Air Inlet and Exhaust System
# *Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.5.1 Inlet Manifold Pressure - Test (Boost at Full Load)

1.5.2 Exhaust Temperature - Test (Measure at Each Cylinder) Units Cyl Observed Cyl Observed
Observed #1 #2

#2 #3 #4

#4 #5 #6

#6 #7 #8

#8 #9 #10

#10 #11 #12

#12 #13 #14

#14 #15 #16

#16 #17 #18

#18 #19 #20

1.5.3 Exhaust Temperature - Test (Measure at Exhaust Stack) Units Cyl Observed
Observed LH

LH RH

1.5.4 Exhaust Stack Backpressure - Test Units Cyl Observed

Observed LH

LH RH
RH Units Observed Specified (+)Tol (-)Tol
1.5.5 Air Shutoff - Test (if equipped)
1.6 Electrical System
# Status Description Units Observed Max Min Comments
1.6.1 1.6.1 Battery Voltage

Engine Stopped

Low Idle

High Idle

1.6.2 Check Battery Electrolyte Level

1.6.3 Starter Draw Test

1.6.4 Genset Engine and Electrical Protective Devices - Check

1.7 Miscellaneous Engine
# Status Description Units Observed Specified (+)Tol (-)Tol Comments
1.7.1

1.7.2

1.7.3
 2. Generator Set
2.1 Annunciator Panel
# Status Description Units Observed Specified (+)Tol (-)Tol Comments
2.1.1 Annunciator Panel - Check

2.1.2 Annunciator Diagnostic Codes - Check

2.1.3 Electrical Connections - Check

2.2 Generator
# *Status Description Units Observed Specified (+)Tol (-)Tol Comments
2.2.1 Generator Bearing(s) - Inspect

2.2.2 Generator Electrical Connections (all) - Check

2.2.3 Electronics Grounding Stud - Check

2.2.4 Generator Package Vibration - Check

2.2.5 Generator Insulation - Check

2.2.6 Generator Rotating Rectifier - Check/Test

2.2.7 Generator Varistor - Test

2.2.8 Generator Space Heater - Check/Test

2.2.9 Generator Stator Lead - Check

Generator Winding Insulation and Resistance Test
2.2.10
with Megohmmeter
2.3 Generator Load Test
# *Status Description Units Observed Specified (+)Tol (-)Tol Comments
2.3.1 Generator Power Output - Check

2.3.2 Generator Power Factor - Check

2.3.3 Generator Stator Winding Temperature - Check

2.3.4 Generator Frequency - Check

2.3.5 Generator Voltage - Check

2.3.6 2.3.6 Generator Bearing Temperature

Front Bearing

Rear Bearing
2.4 Miscellaneous Generator
# *Status Description Units Observed Specified (+)Tol (-)Tol Comments
2.4.1

2.4.2

2.4.3

3. S·O·S
3.1 S·O·S Sampling
# Status Description Obtain Comments
3.1.1 Engine Oil Sample

3.1.2 Engine Coolant Sample (Level II)