- Industrial Engine with Turbochargers
- 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.
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Table 1
Application: |
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Power/RPM: |
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Date : |
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Model: |
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Inspector: |
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SMU: |
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Engine S/N: |
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Work Order # |
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Unit Location: |
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Arrangement #: |
Note: Review Engine & S.O.S. History and check for Active Service Letters prior to inspection. |
Status of the Machine(1) |
The status recommendation of your Industrial Engine is: |
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Show/hide table
(1) |
N = Normal, D = Down Generator , M = Monitor/Needs Attention |
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Visual Inspection
1.0 Prepare Industrial Engine for Inspection
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Table 2
Sl.No. |
Status(1) |
Description |
Comments |
1.1 |
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Prepare the Industrial Engine for the inspection |
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1.2 |
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Download fault codes - ECM data |
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Logged fault codes - ECM data |
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Active fault codes - ECM data |
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1.3 |
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Observe engine exhaust colors |
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1.4 |
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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 |
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Check engine oil level |
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2.2 |
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Engine oil pan |
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2.3 |
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Crankcase breathers and piping |
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2.4 |
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Oil Filters, filter bases, cooler, and lines |
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2.5 |
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Engine mounts, isolators, supports, and rails |
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2.6 |
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Engine/driven equipment coupling |
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2.7 |
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Flywheel housing |
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2.8 |
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Starter motors (Air or Electric) |
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2.9 |
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Air starter lubricator |
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2.10 |
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Prelube pump (if equipped) |
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2.11 |
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Front housing and covers |
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2.12 |
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Crankshaft vibration damper |
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2.13 |
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Cylinder heads |
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2.14 |
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Rocker boxes and valve covers |
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2.15 |
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Injectors |
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2.16 |
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Pulleys, belts (alternator and accessory) |
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2.17 |
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Inspect gauge panel |
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2.18 |
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Inspect engine wiring |
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2.19 |
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Inspect battery terminals, connections, and cables |
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2.20 |
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Inspect guards on driven equipment (if equipped) |
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Show/hide table
(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 |
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Check coolant level |
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3.2 |
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Radiator cap |
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3.3 |
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Pressure relief valve |
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3.4 |
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Radiator cores |
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3.5 |
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Water pumps |
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3.6 |
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Water hoses |
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3.7 |
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Belt guards |
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3.8 |
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Belt tensioner |
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3.9 |
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Fan drive |
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3.10 |
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Fan belt |
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3.11 |
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Screen guard |
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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 |
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Air cleaner elements and housings |
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4.2 |
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Air restriction indicator |
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4.3 |
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Air Inlet and exhaust lines |
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4.4 |
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Exhaust manifolds |
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4.5 |
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Muffler, exhaust stack, and exhaust flexible coupling |
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4.6 |
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Turbochargers |
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4.7 |
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Wastegate |
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4.8 |
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Aftercooler cores |
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4.9 |
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Aftercooler housings |
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Show/hide table
(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 |
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Fuel supply/return lines |
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5.2 |
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Fuel priming pump |
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5.3 |
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Fuel injection lines and retainers |
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5.4 |
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Fuel/water separator |
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5.5 |
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Fuel filters |
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5.6 |
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Fuel day tank |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
6.0 Site Conditions
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Table 7
Sl.No. |
Status(1) |
Description |
Comments |
6.1 |
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Ambient Temperature |
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NORMAL: −18 to 32°C (0 to 90°F) |
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MONITOR: 32 to 46°C (90 to 115°F) or −18° to -29°C (0 to -20°F) |
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ACTION: Above 46° C (115° F) or Below −29° C (−20° F) |
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6.2 |
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Altitude |
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NORMAL: 0 to 1524 m (0 to 5000 ft) |
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MONITOR: 1524 to 3048 m (5000 to 10000 ft) |
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ACTION: Above 3048 m (10000 ft) |
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6.3 |
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Haul Road Grade |
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NORMAL: Flat |
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MONITOR: Mild |
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ACTION: Steep |
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6.4 |
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Haul Road Condition |
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NORMAL: Positive Banking, Gradual Turns, Good Erosion Control |
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ACTION: Negative Banking, Sharp Turns, Poor Erosion Control |
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6.5 |
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Humidity |
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NORMAL: Below 25% |
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MONITOR: 25 to 60% |
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ACTION: Above 60% |
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6.6 |
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Air Quality |
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NORMAL: No Dust |
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MONITOR: Light Dust |
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ACTION: Heavy Dust |
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6.7 |
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Underfoot Condition |
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NORMAL: Dry Flat Surface |
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MONITOR: Moderate Grades, Mixture of Muddy / Dry Surfaces |
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ACTION: Steep Grades, Muddy, Snow, Ice |
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6.8 |
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Machine Utilization |
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NORMAL: 0 to 10 Hours |
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ACTION: Above 10 hours |
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6.9 |
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Equipment Role |
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NORMAL: Utility |
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MONITOR: Support |
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ACTION: Production |
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6.10 |
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Working Material |
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NORMAL: Uncompacted, Low Abrasion |
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MONITOR: Moderately Compacted, Moderate Abrasion |
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ACTION: High Abrasion, Compacted, Dense |
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6.11 |
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Maintenance Practices |
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NORMAL: Excellent |
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MONITOR: Good |
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ACTION: Poor |
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6.12 |
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Primary Industries |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action, Blank = Not Applicable |
Performance Inspection
Engine Performance Checks
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Table 8
Status(1) |
Description |
Specification |
Actual |
Comments |
Maximum |
Minimum |
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Engine Oil Pressure - Record |
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Engine Fuel Pressure - Record |
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Jacket Water Outlet Temperature- Record |
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Aftercooler Outlet Temperature- Record |
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Battery Voltage |
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Engine Stopped |
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Low Idle |
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High Idle |
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Check Battery Electrolyte Level |
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Air inlet Heater Test (if equipped) |
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Starter Draw Test |
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Exhaust Temperature - Record (Measure at Each Cylinder) |
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Cylinder 1 |
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Cylinder 2 |
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Cylinder 3 |
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Cylinder 4 |
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Cylinder 5 |
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Cylinder 6 |
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Cylinder 7 |
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Cylinder 8 |
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Cylinder 9 |
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Cylinder 10 |
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Cylinder 11 |
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Cylinder 12 |
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Cylinder 13 |
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Cylinder 14 |
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Cylinder 15 |
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Cylinder 16 |
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Cylinder 17 |
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Cylinder 18 |
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Cylinder 19 |
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Cylinder 20 |
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Exhaust Temperature - Test (Measure at Exhaust Stack) |
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LH Cylinder |
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RH Cylinder |
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Show/hide table
(1) |
N = Normal, M = Monitor, A = Action, Blank = Not Applicable |