TA2 English - Gas Engine Generator Set [PDF]

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TA-2 Visual & Technical Inspection for Gas Engine Generator Sets SMCS - Job Code - 540 Component Code - 753T



Cat Dealer Address Contact



Customer Address Contact



Serial Number :



Inspector :



Temperature :



Model :



Work Order :



Time :



Engine S/N:



SMU:



Date :



Manufacturer :



Unit Location:



Status of the Gas Engine Generator Set The status recommendation of your Gas Engine Generator Set is:



Normal



Visual Inspection for Gas Engine Generator Sets Status assessment



ü– Normal



M – Monitor



A – Action



Blank – Not Applicable



1. Prepare Gas Engine Generator Set for Inspection #



Status



1.1 1.2



Description 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)



1.5 1.6 1.7 Item No.



Additional Comments



Comments



2. Basic Engine - Inspection #



Status



Description



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 motor(s) (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



2.22 2.23 2.24 Item No.



Additional Comments



Comments



3. Cooling System - Inspection #



Status



Description



3.1



Check coolant level



3.2



Radiator cap



3.3



Pressure relief valve



3.4



Radiator core(s) - Check for Debris



3.5



Water pump(s)



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)



3.13 3.14 3.15 Item No.



Additional Comments



Comments



4. Air Inlet and Exhaust System Inspection #



Status



Description



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 manifold(s)



4.6



Muffler, exhaust stack and exhaust flexible coupling



4.7



Turbocharger(s)



4.8



Wastegate(s)



4.9



Aftercooler core(s)



4.10



Aftercooler housing(s)



4.11 4.12 4.13 Item No.



Additional Comments



Comments



5. Fuel System Inspection #



Status



Description



5.1



Throttle & Actuator Linkage



5.2



Gas Regulator



5.3



Gas Filter



5.4



Carburators



5.5



Gas Shut-off valve



5.6



Gas Lines



Comments



5.7 5.8 5.9 Item No.



Additional Comments



6. Generator Inspection #



Status



Description



6.1



Generator



6.2



Generator set vibration isolators



6.3



Generator coupling guard



6.4



Generator coupling



6.5



Generator leads



6.6 6.7 6.8



Comments



Item No.



Additional Comments



6. Site Conditions # 7.1



Status



Description 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)



7.2



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)



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



7.13 7.14 7.15 Item No.



Additional Comments



Other Remarks



ction for Gas Engine Generator Sets Blank – Not Applicable



epare Gas Engine Generator Set for Inspection Comments



2. Basic Engine - Inspection Comments



3. Cooling System - Inspection Comments



4. Air Inlet and Exhaust System Inspection Comments



5. Fuel System Inspection Comments



6. Generator Inspection Comments



6. Site Conditions



Other Remarks



Technical Inspection for Gas Engine Generator Sets Status assessment



ü- Normal



M - Monitor



A - Action



Blank – Not Applicable



1. Engine 1.1 Cooling System #



Status



1.1.1 1.1.2



Description



Units



Observed



Specified



(+)Tol



(-)Tol



Comments



Units



Observed



Specified



(+)Tol



(-)Tol



Comments



Units



Observed



Specified



(+)Tol



(-)Tol



Comments



Units



Observed



Specified



(+)Tol



(-)Tol



Comments



Radiator Pressure Relief (Radiator Cap) 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 # 1.2.1



*Status 1.2.1



Description Engine Speed - Check Low Idle - no load High Idle - no load



1.2.2



1.2.2



Gas Pressure - Test Gas Pressure at Low Idle Gas Pressure at High Idle



1.2.3



Gas Filter Differential Pressure - Test



1.2.4



Check Fuel Ratio Control (if equipped)



1.2.5



Gas Regulator Condensation - Drain



1.3 Lubrication System # 1.3.1



*Status 1.3.1



Description Engine Oil Pressure - Test Oil Pressure at Low Idle Oil Pressure at High Idle



1.4 Basic Engine #



*Status



1.4.1 1.4.2



Description Check Engine Timing



1.4.2



Inspect Turbocharger (LH) Turbine Wheel (LH) Compressor Impeller (LH)



1.4.3 1.4.4



Check Turbocharger Shaft End Play (LH) 1.4.4



Inspect Turbocharger (RH) Turbine Wheel (RH) Compressor Impeller (RH)



1.4.5



Check Turbocharger Shaft End Play (RH)



1.4.6



Check Air Pressure Regulator for Air Starter (if equipped)



1.4.7



Cylinder Cutout Test



1.4.8



Engine Crankcase Pressure (Blowby) - Test



1.4.9



Engine Crankcase Pressure - Test



1.5 Air Inlet and Exhaust System #



*Status



1.5.1



Description



Units



Observed



Specified



(+)Tol



(-)Tol



Comments



Inlet Manifold Pressure - Test (Boost at Full Load)



1.5.2



Exhaust Temperature - Test (Measure at Each Cylinder)



Units



Cyl



Observed



Cyl



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



Observed



RH Exhaust Stack Backpressure - Test



Units



Observed



Cyl



Observed



LH



LH



RH



RH 1.5.5



Observed



LH



LH 1.5.4



Cyl



Observed



Units



Observed



Specified



(+)Tol



(-)Tol



Units



Observed



Specified



(+)Tol



(-)Tol



Units



Observed



Specified



(+)Tol



(-)Tol



Units



Observed



Max



Units



Observed



Specified



Air Shutoff - Test (if equipped)



1.5.6



Intake Condensation - Drain



1.5.7



Measure Fumes Disposal Filter Differential



1.6 Electrical System # 1.6.1



Status 1.6.1



Description



Min



Comments



Battery Voltage Engine Stopped Low Idle High Idle



1.6.2



Check Battery Electrolyte Level



1.6.3



Check Battery Charger



1.6.4



Starter Draw Test



1.6.5



Engine Protective Devices - Check for proper operation



1.7 Miscellaneous Engine # 1.7.1 1.7.2 1.7.3



Status



Description



(+)Tol



(-)Tol



Comments



2. Generator Set 2.1 Annunciator Panel #



Status



Description



2.1.1



Annunciator Panel - Check



2.1.2



Annunciator Diagnostic Codes - Check



2.1.3



Electrical Connections - Check



Units



Observed



Specified



(+)Tol



(-)Tol



Comments



Units



Observed



Specified



(+)Tol



(-)Tol



Comments



Units



Observed



Specified



(+)Tol



(-)Tol



Comments



Units



Observed



Specified



(+)Tol



(-)Tol



Comments



2.2 Generator #



*Status



Description



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



2.2.10



Generator Winding Insulation and Resistance Test with Megohmmeter



2.3 Generator Load Test #



*Status



Description



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 2.3.6



Generator Voltage - Check 2.3.6



Generator Bearing Temperature Front Bearing Rear Bearing



2.4 Miscellaneous Generator #



*Status



Description



2.4.1 2.4.2 2.4.3



3. S·O·S 3.1 S·O·S Sampling #



Status



Description



3.1.1



Engine Oil Sample



3.1.3



Engine Coolant Sample (Level II)



Obtain



Comments