TA-2 Visual & Technical Inspection for

Gas Engine 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:

Status of the Gas Engine Generator Set

Normal
The status recommendation of your Gas Engine Generator Set is:
 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 Description Comments

1.1 Prepare the Gas Engine Generator Set for the inspection

1.2
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

 2. Basic Engine - Inspection
# Status 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 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

 3. Cooling System - Inspection
# Status Description Comments
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

 4. Air Inlet and Exhaust System Inspection
# Status 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 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

 5. Fuel System Inspection
# Status Description Comments
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

5.7

5.8

5.9

Item No. Additional Comments

6. Generator Inspection
# Status Description Comments
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
Item No. Additional Comments

6. Site Conditions
# Status Description
7.1 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)
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 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 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
# *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 Check Engine Timing

1.4.2 1.4.2 Inspect Turbocharger (LH)

Turbine Wheel (LH)

Compressor Impeller (LH)

1.4.3 Check Turbocharger Shaft End Play (LH)

1.4.4 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 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)
Units Observed Specified (+)Tol (-)Tol

1.5.6 Intake Condensation - Drain

Units Observed Specified (+)Tol (-)Tol

1.5.7 Measure Fumes Disposal Filter Differential

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 Check Battery Charger

1.6.4 Starter Draw Test

1.6.5 Engine Protective Devices - Check for proper operation

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

3.1.3 Engine Coolant Sample (Level II)