3500 3500 Star Star tup tu p & Commis Commi ssi oni n g Che Ch eckl i st Gens Gen set Cove Co verr Sh eet I t a l ic ic i z e d I t e m s r e l a t e t o T i e r I V C o m p l i a n c e
SERVICE REPRESENTATIVE: Selling Dealer:
Service Request #:
Service Engineer: Selling Dealer Address:
City:
State/Province/Country:
Zip Code:
Date of Service: Commissioning Date: Service Dealer (if Different than Selling Dealer): Service Dealer Address:
City
State/Province/Country:
Zip Code:
LOCATION OF THE SYSTEM: Customer Name:
Project Name (if applicable):
Street Address:
City:
State/Province/Country:
Zip Code:
Main Contact Name:
Telephone Number:
Alt. Contact Name:
Telephone Number:
PRODUCT INFORMATION Engine Serial #:
Generator Set Serial #:
Engine Arrangement #:
Generator Serial #:
Engine Model Group:
Generator Arrangement #:
Type of installation:
Generator Model #:
Rated Speed:
Voltage:
Low Idle:
Frequency:
High Idle:
Amperage:
Timing: Set Point Timing Verfified: Engine Derate: SI units or Imperial
Rating:
Yes No N/A
Fuel Type: Delegated final assembly contract #:
ENVIROMENTAL CONDITIONS Ambient Temperature:
Elevation:
Engine Room Temp:
Relative Humidity:
Atmospheric Conditions: STORAGE AND INSULATION Generator Dried for 48 Hours Before Start-up (See SEHS9124):
Visual Inspection Before Start-up -- Grease, Water, Debris, (Foreign Material) Yes No N/A
Yes No N/A
Drying Method:
INSTALLING ELECTRICIAN: ELECTRICIAN: Company Name: Electrician Name:
Telephone Number:
Service Literature As Built Drawings Delivered?
Yes No N/A Customer Acceptance Test:
All Configurations, Logic, Set Points and Programs Saved to Backup Media?
Yes No N/A Yes No N/A
Please List all Lliterature that was Delivered and Reviewed:
SERVICE BULLETINS (List All Service Bulletins Addressed Addressed During this Visit):
INSTALLATION AND LOAD 1 Neutral Grounding Systems
Yes No N/A
10 Unit connected in parallel
Yes No N/A
2 Enclosure Weather Tight
Yes No N/A
11 Load Diagram Created & Saved
Yes No N/A
3 Proper Ventilation
Yes No N/A
12 Full Load Data Created & Saved
Yes No N/A
4 Description of load 5 Moto Motorr SKVA SKVA 6 Motor Total HP 7 UPS Manufacturer 8 UPS Model Number/Size 9 UPS Serial Number COMMENTS AND RECOMMENDATIONS:
CUSTOMER AUTHORIZATION TO SERVICE/TEST: Customer Rep. Signature:
Date:
Service Engineer Signature:
Date:
Was Customer Offered ESC?
Yes No N/A
If no, why not?
SITE SPECIFICATIONS: Job delays and problems:
Automatic Transfer Switch 1 Manufacturer: 2 Model number: 3 Serial number:
1 Verify voltage/amperage
Yes No N/A
2 Verify phase rotation
Yes No N/A
3 Set all timers & exerciser
Yes No N/A
4 Check for damage
Yes No N/A
5
Check for loose or missing hardware
Yes No N/A
6
All wires secure & check wire terminations
Yes No N/A
7 Test for proper operation
CUSTOMER ACCEPTANCE: Start-up and commissioning is complete within factory standards. Customer Rep. Signature:
Date:
Service Engineer Signature:
Date:
Yes No N/A
CATERPILLAR 3500 SERIES GENSET START-UP & COMMISSIONING CHECKLIST
CAUTION! Only qualified personnel who have been trained to support the product should attempt to proceed with startup. Note: Service Engineer must communicate with customer to understand site requirements for Personal Protective Equipment (PPE), Lockout and other safety procedures. Note: Italicized Items relate to Tier IV Comp liance
Start-up 1. Safety and Serviceability 1 Genset is free of damage
Yes No N/A
12 Fire extinguisher present & charged
Yes No N/A
2 Hot pipes are wrapped
Yes No N/A
13 Fire suppression unlocked & operational
Yes No N/A
3 All hoses, piping & wiring is/are secure
Yes No N/A
14 Pipe work & services are color coded/labeled
Yes No N/A
4 Spillage containment acceptable
Yes No N/A
15 Remote start/stop checked & operational
Yes No N/A
5 Personal protection equipment worn
Yes No N/A
16 Emergency stop functional
Yes No N/A
6 Floors are clean no hazards
Yes No N/A
17 Sight glasses are visible
Yes No N/A
7 Floor openings are covered
Yes No N/A
18 Gauges are functional (oil, fuel, air, other…)
Yes No N/A
8 Genset is level with all holding bolts secure
Yes No N/A
19 Proper grounding (refer to REHS4634)
Yes No N/A
9 Warning decals & plates are installed
Yes No N/A
20 Air intake free of airborne debris
Yes No N/A
10 All guards and heat shields are in place
Yes No N/A
Yes No N/A
11 All safety shutdowns & warnings operational
Yes No N/A
21 Air supply system maintanance service intervals a minium of 4500 hours (if engine manuafacturer solution is not used)
1 Properly sized fuel lines
Yes No N/A
12 Check for fuel leaks
Yes No N/A
2 Fuel transfer pump properly installed
Yes No N/A
13 Critical fuel level shutdown
Yes No N/A
3 Tank fuel level is verified
Yes No N/A
14 Proper operation of fuel tank alarms
Yes No N/A
4 Fuel tank mounting is level
Yes No N/A
15 High fuel level gauge stops pump
Yes No N/A
5 Fuel filter primed
Yes No N/A
16 Properly connected fuel return/overflow lines
Yes No N/A
6 Fuel filter not damaged
Yes No N/A
17 Fuel cooler installed (external)
Yes No N/A
7 Properly vented fuel tanks
Yes No N/A
18 Shutoff valves are operating properly
Yes No N/A
8 Fuel tank plugs properly installed
Yes No N/A
19 Solenoid valve operating properly
Yes No N/A
9 Off package fuel lines are proper material
Yes No N/A
20 Using bio-diesel
Yes No N/A
10 Foot valve installed & operational
Yes No N/A
21 If so, what percent
11 Correct valve installed in the return
Yes No N/A
22 ULSD sticker on all fuel filling points
Notes:
2. Fuel System and Fuel Storage
Notes:
Yes No N/A
3. Lube System 1 Jacket oil heater operational
Yes No N/A
8 Check for leaks
Yes No N/A
2 Oil sample taken (SOS)
Yes No N/A
9 Oil pressures within specifications
Yes No N/A
3 Oil level is correct
Yes No N/A
10 Oil meets specifications
Yes No N/A
4 Pipes routed through front end of base
Yes No N/A
11 Pre-lubrication system installed
Yes No N/A
5 Remove crankcase covers, plugs & tape
Yes No N/A
12 Check pre-lube installation
Yes No N/A
6 Install crankcase breather hose if necessary; check for proper installation & routing
Yes No N/A
13 CAT DEO-ULS/ API CJ 4 oil sticker on all engine lube filling points
Yes No N/A
7 Oil make-up system installed
Yes No N/A
14 Oil renewal system present
Yes No N/A
1 Low water level
Yes No N/A
16 High air inlet manifold temperature
Yes No N/A
2 High water temperature
Yes No N/A
17 High / low battery voltage
Yes No N/A
3 Low water temperature
Yes No N/A
18 Jacket water pressure
Yes No N/A
4 Low oil pressure
Yes No N/A
19 Rupture basin
Yes No N/A
5 Low oil level
Yes No N/A
20 Temperature detectors connected
Yes No N/A
6 Low fuel level
Yes No N/A
21 Engine warning lamp communicated to operator
7 High fuel level
Yes No N/A
8 Over speed
Yes No N/A
9 E-Stop
Yes No N/A
communicated to operator (J1939 or lamp)
10 Crank termination systems
Yes No N/A
23 Diesel particulate filter warning communicated
11 Low DC Voltage
Yes No N/A
12 Over crank
Yes No N/A
13 Battery charger
Yes No N/A
14 Fire alarm
Yes No N/A
15 Shutdown device
Yes No N/A
Notes:
4. Alarm Verification
(J1939 or lamp) 22 High exhaust system temperature
to operator (J1939 or lamp) 24 "Regeneration System Disabled" communicated to operator (J1939 or lamp) 25 Force/Disable Regneration control communicated to operator (J1939 or lamp)
Notes:
5. Governor Settings 1 Copy saved of the ECM replacement file or other record governor settings saved 2 Was the engine ordered as a constant or variable speed engine
Notes:
Yes No N/A
3 Is the engine installed as a constant or variable speed engine
6. Intake System/Exhaust System 1 Check for damage
Yes No N/A
21 Rise over ambient to engine air inlet temp sensor (5C maximum)
Yes No N/A
2 Remove air filter bags / covers
Yes No N/A
22 Inlet temperature sensor in the inlet flow path
Yes No N/A
3 Air filter gasket serviceable / accessible
Yes No N/A
23 If no, describe location
4 Check exhaust cowl & rain cap
Yes No N/A
5 Check exhaust water drain pipe work & valves
Yes No N/A
24 Exhaust backpressure at turbo outlet
6 Condensate drain provided
Yes No N/A
25 Use of engine manufacturer Supplied Flex Kit for engine exhaust - if yes record part #
7 Air filter housing seal present & serviceable
Yes No N/A
26 Use of engine manufacturer Supplied Flex Kit for aftertreatment inlet - if yes record part #
8 Check for missing or loose hardware
Yes No N/A
27 Use of engine manufacturer Supplied Flex Kit for aftertreatment outlet - if yes record part #
9 Pre-lube turbo charger
Yes No N/A
28 If no, you must have written document of engine manufacturer's approval. Record flex kit
10 Drain valves fitted relative to exhaust system
Yes No N/A
description here or in the Notes space below
11 Exhaust directed away from building / personnel
Yes No N/A
29 Exhaust wrapping about flex joint approved
Yes No N/A
12 Acceptable size of supply air - intake
Yes No N/A
30 Verify pipe material (16 gage) and thickness (1.5 4 mm) for turbo to CEM connection
Yes No N/A
13 Check intake air systems (sized properly per A&I specifications)
Yes No N/A
31 Charge air cooling system 100% manufacturer supplied and factory installed, and free of
Yes No N/A
14 Check intake and exhaust systems for leaks
Yes N o N/A
obstructions to external cooling flow
15 Check for duct isolation
Yes No N/A
32 Charge air cooler restriction test (15kPa)
Yes No N/A
16 Emissions control unit installed & operational
Yes No N/A
33 Charge air cooler capability test, ATAAC outlet
Yes No N/A
o
temperature (unmixed) (50 C)
Notes:
17 Exhaust pipe properly supported
Yes No N/A
34 Verify urea (monitoring level and storage) matches TMI specifications
Yes No N/A
18 Flexible exhaust fitting to isolate vibrations and allow for thermal expansion
Yes No N/A
35 Verify air pressure supply is with 60-120 psi, and maximum allowable pressure drop from air source to injector nozzle is not exceeded
Yes No N/A
19 Maximum air inlet restriction at turbo compressor inlet - clean filter (3.7kPa)
Yes No N/A
36 DEF liquid pressure at inlet to dosing cabinet is within range 2-5 psi at full load operation
Yes No N/A
20 Air inlet restriction indicator setting (6.2kPa)
Yes No N/A
37 All emissions labels visible - record location(s) below if not visible
Yes No N/A
7. Aftertreatment 1 Ball joint/slip joint/bellows properly installed
Yes No N/A
2 Installation must meet one of the following requirements
23 Air compressor filter meet EPA requirements
Yes No N/A
24 Air compressor meet demand of dosing module
Yes No N/A
a) Turbo to CEM inlet exhaust pipe length 366 cm or less
Yes No N/A
25 Air compressor lines properly sized and have no P traps
Yes No N/A
b) Turbo to CEM inlet temperature drop @ 10%
Yes No N/A
26 Engine mounted air compressor supply pre-boosted (only pre-boosted is allowed)
Yes No N/A
3 Turbo to CEM pipe fully insulated
Yes No N/A
27 DEF tank material meet requiremetns in A&I Guide
Yes No N/A
4 CEM oriented parallel to horizon +/- 5 degrees
Yes No N/A
28 DEF filter meet requiremetns in A&I Guide
Yes No N/A
5 Turbo outlet to CEM inlet temperature drop at full load
Yes No N/A
29 Ratio of 1 fuel tank refill to 1 DEF tank refill for systems with a constantly visible DEF level indicator
Yes No N/A
6 Communicate that top of CEM is not suitable for a work platform
Yes No N/A
30 Ratio of 2 fuel tank refills to 1 DEF tank refill for systems without a constantly visible DEF level indicator
Yes No N/A
7 Dust Ejector connected after the CEM
Yes No N/A
31 DEF tank protected against frozen urea blocking passage
Yes No N/A
32 DEF tank sample port installed
Yes No N/A
o
load 10 C or less
8 Describe Dust Ejector connection location 9 Dosing cabinet a maximum of 20 feet (6m) from CEM
Yes No N/A
33 Exhaust connected properly
Yes No N/A
10 Top of dosing cabinet at or below bottom of CEM mounting pads
Yes No N/A
34 Exhaust weight transfer to CEM meets A&I specification
Yes No N/A
11 Dosing cabinet a maximum of 100 feet (30m) from engine
Yes No N/A
35 Engine to CEM inlet connection 400 Nm
Yes No N/A
12 Dosing cabinet ambient temperature -40 o C to
Yes No N/A
36 CEM to atmosphere connection 100 Nm
Yes No N/A
13 Dosing cabinet mounted not more than 18 degrees from vertical
Yes No N/A
37 Customer supplied wiring harness properly routed
Yes No N/A
14 Area around dosing cabinet unobstructed
Yes No N/A
38 Customer supplied wiring harness not kinked, mounted away fro mheat sources, properly supported, and marked as not a step
Yes No N/A
15 Dosing cabinet air connection as specified in A&I Guide
Yes No N/A
39 Customer supplied wiring harness meets the wire specifications for material and length as specified in the wiring diagram
Yes No N/A
16 Dosing cabinet air connection location as specified in A&I Guide
Yes No N/A
40 Customer supplied wiring harness matches the pin out as specified in the wiring diagram
Yes No N/A
17 Dosing cabinet vent line routed to storage tank or approved drain
Yes No N/A
41 Dosing cabinet to CEM urea lines routed properly
Yes No N/A
18 Dosing cabinet vent line exit below injector height
Yes No N/A
42 Dosing cabinet to CEM urea lines not kinked, mounted away from heat sources, properly supported, and marked as not a step
Yes No N/A
19 No low spots in dosing cabinet vent line
Yes No N/A
43 Main tank to dosing cabinet urea lines routed properly
Yes No N/A
20 Urea quality meets ISO22241-1
Yes No N/A
44 Main tank to dosing cabinet urea lines material meets specifications in A&I Guide
Yes No N/A
21 Dosing cabinet AC supply meets requirements in A&I Guide
Yes No N/A
45 Urea lines meet urea pump requirement for line restriction
Yes No N/A
22 Dosing cabinet DC supply meets requirements in A&I Guide
Yes No N/A
46 Urea lines connected properly
Yes No N/A
o
50 C
*Aftertreatment section continued on next page
47 Air lines maintain the air quality as specified in the A&I Guide
Yes No N/A
51 Dosing cabinet air supply meet air quality requirements in A&I Guide
Yes No N/A
48 Air lines routed and mounted properly
Yes No N/A
52 Air lines not kinked, mounted away from heat
Yes No N/A
49 Air lines connected properly
Yes No N/A
sources, properly supported, and marked as not
50 Air compressor appropriate for environment
Yes No N/A
a step
Notes:
8. Jacket Water & Space Heater 1 Jacket water heater wiring and voltage correct
Yes No N/A
5 Space heater thermostat is installed
Yes No N/A
2 Jacket water heater bleed off air required
Yes No N/A
6 Space heater functioning properly
Yes No N/A
3 Verify JWH valve position is open during usage
Yes N o N/A
7 Space heater operated 48 hours before start-up
Yes N o N/A
4 Space heater is off while engine is running
Yes No N/A
Notes:
9. Starter & Battery 1 Confirm auto start
Yes No N/A
11 Battery charging alternator operational check
Yes No N/A
2 Inspect starter wiring
Yes No N/A
12 Batteries connected properly
Yes No N/A
3 Starter operational check
Yes No N/A
13 Batteries isolated from floor
Yes No N/A
4 Cycle crank timer
Yes No N/A
14 Batteries charged (deep cycle) before use
Yes No N/A
5 Check oil lubrication
Yes No N/A
15 Battery cables & racks properly installed
Yes No N/A
6 Air/hydraulic compressor operational
Yes No N/A
16 Proper electrolyte level & proper specific gravity
Yes No N/A
7 Isolation valves correctly positioned
Yes No N/A
17 Proper system voltage
Yes No N/A
8 Condensate drain provided
Yes No N/A
18 Trickle charger
Yes No N/A
9 Check high & low air / hydraulic pressure
Yes No N/A
19 Charging alternator guards in place & secure
Yes No N/A
Yes No N/A
20 Charging alternator belts properly inspected and adjusted
Yes No N/A
10 Check battery boosts / float controls
Notes:
10. Cooling System 1 Check for leaks
Yes No N/A
10 High water temperature shutdown
Yes No N/A
2 Check coolant level
Yes No N/A
11 Expansion tank highest level
Yes No N/A
3 Check for damage & unusual noise
Yes No N/A
12 All guards & shrouds installed with proper
Yes No N/A
4 Filler cap & seal installed properly
Yes No N/A
13 Discharge air unobstructed
Yes No N/A
5 Check antifreeze (refer to A&I Guide)
Yes No N/A
14 Cooling fan control strategy documented and verified
Yes No N/A
6 Isolation valves & drain valves installed
Yes No N/A
15 Customer controlled fan: record ATAAC outlet temperature when fan fully on at rated power o
Yes No N/A
o
(50 C maximum with 30 C ambient). Adjust resulting IMAT temperature for ambient test
7 Drain valves routed correctly
Yes No N/A
8 Correct condition, alignment, and tension of fan belts / pulleys
Yes No N/A
16 Customer controlled fan: record jacket water outlet temp when fan fully on
9 Auxiliary supply voltage to fans correct
Yes No N/A
17 Verify sufficient cooling/air flow provisions per A&I guide
o
conditions 1 for 1 back to the 30 C ambient reference.
Yes No N/A
Notes:
11. Mechanical
Notes:
1 Package properly mounted
Yes No N/A
4 Over speed shut-down is correct
Yes No N/A
2 Package supports & vibration isolators installed
Yes No N/A
5 Over-crank shut-down is correct
Yes No N/A
3 Air shut-off is operational
Yes No N/A
6 Motorized dampers are operational
Yes No N/A
12. Gen Syst - Electrical 1 Check AC & DC electrical
Yes No N/A
10 Over voltage protection
Yes No N/A
2 Check for loose wiring & secure
Yes No N/A
11 Over current protection
Yes No N/A
3 Verify phase sequence of wiring
Yes No N/A
12 Check diodes
Yes No N/A
4 Confirm stator RTD's are functional
Yes No N/A
13 Correct generator wiring configuration
Yes No N/A
5 Annunciators installed & wiring is complete
Yes No N/A
14 Unit is properly grounded (REHS4632)
Yes No N/A
6 Electrical bonding of services is complete
Yes No N/A
15 Adjust voltage
Yes No N/A
7 Interconnects complete & ready for load test
Yes No N/A
16 All covers are in position
Yes No N/A
8 Connections completed to transfer switch
Yes No N/A
17 Adjust frequency
Yes No N/A
9 Fuse & fuse ratings are verified
Yes No N/A
18 Complete generator alignment process
Yes No N/A
Notes:
13. Gen Syst - Control Panel 1 Secure all wires
Yes No N/A
9 Check generator system controls
Yes No N/A
2 Check all wire terminations for tightness
Yes No N/A
10 Verify settings (correct as needed)
Yes No N/A
3 Energize set & system controls
Yes No N/A
11 Check software & upload latest version
Yes No N/A
4 Verify operation of annunciator
Yes No N/A
12 Check condition / operation of meters
Yes No N/A
5 Check auto / manual stop operation
Yes No N/A
13 Remote emergency stop wired / functional
Yes No N/A
6 Check generator local controls
Yes No N/A
14 Calibrations are checked
Yes No N/A
7 Check generator remote controls
Yes No N/A
15 Select set parameters on system (ECM
Yes No N/A
8 Verify interconnect wiring
Yes No N/A
download)
Notes:
14. Gen Syst - Mechanical 1 Check for loose or missing hardware
Notes:
Yes No N/A
2 Check crankshaft deflection / end play
Yes No N/A
15. Gen Syst - Circuit Breakers 1 Test any alarms / shunt trip
Yes No N/A
3 Verify against generator Volts / Amps
Yes No N/A
2 Check for tight connections
Yes No N/A
4 Set circuit breaker trip unit for site conditions
Yes No N/A
1 All settings verified
Yes No N/A
4 Install latest software version
Yes No N/A
2 Check cross current compensation circuit
Yes No N/A
5 VR PID loop gains configured and recorded
Yes No N/A
3 Check voltage power factor regulation
Yes No N/A
Notes:
16. Gen Syst - Voltage Regulators
Notes:
17. Automatic Transfer Switch
Notes:
1 Check for damage
Yes No N/A
5 Verify voltage/amperage
Yes No N/A
2 Check for loose or missing hardware
Yes No N/A
6 Set all timers & exerciser
Yes No N/A
3 All wires secure & check wire terminations
Yes No N/A
7 Verify phase rotation
Yes No N/A
4 Test for proper operation
Yes No N/A
Commissioning 1. Safety and Serviceability 1 Personal protection equipment worn
Yes No N/A
14 Gauges are functional (oil, fuel, air, other…)
Yes No N/A
2 Floors are clean no hazards
Yes No N/A
15 Proper grounding (refer to REHS4634)
Yes No N/A
3 Floor openings are covered
Yes No N/A
16 Air intake free of airborne debris
Yes No N/A
4 Genset is level with all holding bolts secure
Yes No N/A
17 Access routes unobstructed
Yes No N/A
5 Warning decals & plates are installed
Yes No N/A
18 Overhead obstructions are clearly marked
Yes No N/A
6 All guards and heat shields are in place
Yes No N/A
19 Overhead & side clearance is acceptable
Yes No N/A
7 All safety shutdowns & warnings operational
Yes No N/A
20 Adequate access to fluid fill areas to prevent spills
Yes No N/A
8 Fire extinguisher present & charged
Yes No N/A
21 Air/oil/fuel filters are accessible
Yes No N/A
9 Fire suppression unlocked & operational
Yes No N/A
22 Level indicators are accessible
Yes No N/A
10 Pipe work & services are color coded/labeled
Yes No N/A
23 Key components are labeled
Yes No N/A
11 Remote start/stop checked & operational
Yes No N/A
24 Engine room noise level policy satisfied
Yes No N/A
12 Emergency stop functional
Yes No N/A
25 No unauthorized access
Yes No N/A
13 sight glasses are visible
Yes No N/A
Notes:
2. Maintenance and Coverage
Reviewed start-up procedure & safety information
Yes No N/A
1 Reviewed OMM, Parts Manual, Warranty, SOS & service needs
Yes No N/A
6 Copy of ESC form saved in dealer records
Yes No N/A
2 CSA was offered to the customer
Yes No N/A
7 Has operator / maintenance supervisor been trained on engine operation and maintenance
Yes No N/A
3 CSA was accepted by the customer
Yes No N/A
8 Special requirements & testing
Yes No N/A
4 ESC was offered to the customer
Yes No N/A
9 Additional parts purchased or ordered
Yes No N/A
5 ESC was accepted by the customer
Yes No N/A
Notes:
3. Fuel System and Fuel Storage
Notes:
1 Check for fuel leaks
Yes No N/A
6 Solenoid valve operating properly
Yes No N/A
2 Critical fuel level shutdown
Yes No N/A
7 High fuel level gauge stops pump
Yes No N/A
3 Proper operation of fuel tank alarms
Yes No N/A
8 Fuel system schematic created/saved
Yes No N/A
4 Properly connected fuel return/overflow lines
Yes No N/A
9 Fuel pressure matches TMI specification
Yes No N/A
5 Shutoff valves are operating properly
Yes No N/A
4. Lube System 1 Oil level is correct
Yes No N/A
3 Oil pressures within specifications
Yes No N/A
2 Check for leaks
Yes No N/A
4 Oil meets specifications
Yes No N/A
Notes:
5. Alarm Verification 1 Low water level
Yes No N/A
11 Low DC Voltage
Yes No N/A
2 High water temperature
Yes No N/A
12 Over crank
Yes No N/A
3 Low water temperature
Yes No N/A
13 Battery charger
Yes No N/A
4 Low oil pressure
Yes No N/A
14 Fire alarm
Yes No N/A
5 Low oil level
Yes No N/A
15 Shutdown device
Yes No N/A
6 Low fuel level
Yes No N/A
16 High air inlet manifold temperature
Yes No N/A
7 High fuel level
Yes No N/A
17 High / low battery voltage
Yes No N/A
8 Over speed
Yes No N/A
18 Jacket water pressure
Yes No N/A
9 E-Stop
Yes No N/A
19 Rupture basin
Yes No N/A
Yes No N/A
20 Temperature detectors connected
Yes No N/A
1 Check intake and exhaust systems for leaks
Yes No N/A
9 Emission level verified within specifications
Yes No N/A
2 Check intake air systems (sized properly per A&I specifications)
Yes No N/A
10 Record boost (inlet manifold) pressure:
3 Check for duct isolation
Yes No N/A
11 Record temperature after cooler:
4 Emissions control unit installed & operational
Yes No N/A
12 Exhaust temperature (pre turbo) at full load:
5 Flexible exhaust fitting to isolate vibrations and allow for thermal expansion
Yes No N/A
13 Exhaust port temperatures at full load
6 Create / save air supply / exhaust layout
Yes N o N/A
14 Record air filter differential pressure:
7 Ensure proper exhaust system back pressure per specifications
Yes No N/A
15 Record exhaust temperature stack:
8 Exhaust leg pressure differential less than 1kPa
Yes No N/A
16 Record intake manifold air temperature:
10 Crank termination systems
Notes:
6. Intake System/Exhaust System
Notes:
7. Aftertreatment 1 Following initial start-up procedure from Appendix B in the A&I guide
Yes No N/A
12 DEF tank venting meet fumes leak requirements
Yes No N/A
2 Back pressure differential before CEM 1kPA
Yes No N/A
13 DEF tank venting routed to meet local and OSHA guidelines for ammonia fumes
Yes No N/A
14 Low urea level warning in time to prevent shutdown
Yes No N/A
3 CEM temperature increase due to proximity of external heat source 4 Maximum 1L water accumulation at 5 degree tilt
Yes No N/A
15 If exhaust connection supplied by Caterpillar, see TMI for value and include in customer allowance (Not to exceed 6kPa)
5 Dosing cabinet air pressure/air flow at customer supplied compressor as listed in A&I Guide
Yes No N/A
16 If exhaust connection supplied by customer, measure and include in customer allowance (Not to exceed 6kPa)
6 Dosing cabinet urea pressure 2-5 psi (14-35 kPa) at 1.25-2.5 gal/min (4.7-9.5 l/min) flow
Yes No N/A
17 Engine to CEM temperature drop does not exceed maximum figure in A&I Guide
Yes No N/A
7 Dosing Cabinet air supply a minimum of 105 psi (724 kPa) within 3 minutes
Yes No N/A
18 Maximum 6 kPa difference from CEM to atomospheric pressure
Yes No N/A
8 Compressor capable of delivering 10 cfm for 30 seconds and still maintain a tank pressure gretaer than 80 psi (550 kPa)
Yes No N/A
19 Urea lines meet dosing cabinet requirements of 2-5 psi (14-34.5 kPa) at 1.25-2.5 gal/min (5-9.5 l/min)
Yes No N/A
9 Dosing cabinet air supply capable of 0-10 SCFM
Yes No N/A
20 Urea lines temperature between -5 o C and 50 o C
Yes No N/A
10 DEF tank temperature between -5 o C and 50 o C
Yes No N/A
21 Air lines allow dosing pressure and flow rate specified in A&I Guide
Yes No N/A
11 DEF tank venting affect head pressure
Yes No N/A
22 Air lines maintain temperature between -40 o C and
Yes No N/A
o
50 C
Notes:
8. Jacket Water & Space Heater
Notes:
1 Space heater functioning properly
Yes No N/A
3 Adjust thermostat JWH record setting
2 Space heater operated 48 hours before start-up
Yes No N/A
4 Record block temperature
Yes No N/A
9. Starter & Battery 1 Confirm auto start
Yes No N/A
3 Charging alternator belts properly inspected and adjusted
2 Charging alternator guards in place & secure
Yes No N/A
4 Charge Rate (need data value):
1 High water temperature shutdown
Yes No N/A
6 Verify sufficient cooling provisions
2 Expansion tank highest level
Yes No N/A
7 Coolant mixing ratios
3 All guards & shrouds installed with proper clearance
Yes No N/A
8 Jacket water heater supply (Volts / Amps)
4 Discharge air unobstructed
Yes No N/A
9 Pressure test (record PSI)
5 Hot air recirculation prevented
Yes No N/A
Yes No N/A
Notes:
10. Cooling System Yes No N/A
10 Differential Temperature Radiator (ref. to A&I
Notes:
11. Mechanical 1 Air shut-off is operational
Yes No N/A
4 Motorized dampers are operational
Yes No N/A
2 Over speed shut-down is correct
Yes No N/A
5 Inspect package supports and vibration isolators
Yes No N/A
3 Over-crank shut-down is correct
Yes No N/A
6 Inspect package for proper mounting
Yes No N/A
1 Unit is properly grounded (REHS4632)
Yes No N/A
3 All covers are in position
Yes No N/A
2 Adjust voltage
Yes No N/A
4 Adjust frequency
Yes No N/A
Notes:
12. Gen Syst - Electrical
Notes:
13. Gen Syst - Control Panel 1 Verify settings (correct as needed)
Yes No N/A
4 Remote emergency stop wired / functional
Yes No N/A
2 Check software & upload latest version
Yes No N/A
5 Calibrations are checked
Yes No N/A
3 Check condition / operation of meters
Yes No N/A
6 Select set parameters on system (ECM download)
Yes No N/A
Yes No N/A
Notes:
14. Gen Syst - Mechanical 1 Check for loose or missing hardware
Yes No N/A
Notes:
15. Gen Syst - Circuit Breakers
Notes:
1 Test any alarms / shunt trip
Yes No N/A
4 Set circuit breaker trip unit for site conditions
2 Check for tight connections
Yes No N/A
5 Record circuit breaker settings:
3 Verify against generator Volts / Amps
Yes No N/A
16. Gen Syst - Voltage Regulators
Record Values in boxes provided
LOAD Exciter Field (F1,F2)
Volts DC
Exciter Field (F1,F2)
Amps DC
Sensing Line (T1,T2)
Volts AC
Sensing Line (T1,T3)
Volts AC
Sensing Line (T2,T3)
Volts AC
PMG output (1 to 2)
Volts AC
PMG output (1 to 3)
Volts AC
PMG output (2 to 3)
Volts AC
NO LOAD Exciter Field (F1,F2)
Volts DC
Exciter Field (F1,F2)
Amps DC
Sensing Line (T1,T2)
Volts AC
Sensing Line (T1,T3)
Volts AC
Sensing Line (T2,T3)
Volts AC
PMG output (1 to 2)
Volts AC
PMG output (1 to 3)
Volts AC
PMG output (2 to 3)
Volts AC
1 VR PID loop gains configured
Yes No N/A
2 VR PID loop Gains recorded
Yes No N/A
3 CDVR/ECM replacement file saved
Yes No N/A
2 Verify phase rotation
Yes No N/A
Notes:
17. Automatic Transfer Switch 1 Verify voltage/amperage
Notes:
Yes No N/A
Start-up and Commissioning 1. Insulation Test Reference Doc. (Service Information System): SEHS9124 Click on media search, enter SEHS9124 in media number field Insul. Test
30 Second
60 Second
30 Second
60 Second
Reading
Reading
Corrected
Corrected
30 Second
60 Second
30 Second
60 Second
Reading
Reading
Corrected
Corrected
Beg. of storage-Main Stator Winding Temp. Comments: Beg.of storage-Main Rotor Winding Temp. Comments: Beg. of storageExcitor Stator Winding Temp. Comments: Beg. of storageExcitor Rotor Winding Temp. Comments: Beg. of storage-PMG Stator Winding Temp. Comments:
Start-up-Main Stator Winding Temp. Comments: Start-up-Main Rotor Winding Temp. Comments: Start-upExcitor Stator Winding Temp. Comments:
*Insulation Test continued next page
Start-upExcitor Rotor Winding Temp. Comments: Start-up-PMG Stator Winding Temp. Comments: Insulation Test Equipment Description:
Notes:
2. Vibration Levels Vibration Levels - 1 1 Vibration isolator manufacturer: 2 Vibration isolator model: 3 Vibration isolator serial number: 4 Vibration test equipment description - (Model, serial# & calibration date): 5 Order=(vibration frequency/engine RPM) Vibration levels used for - use for all packages excluding in-line 6 (e.g. C9, C15, C18, 3406, 3456C…) Built after 1/1/04 Reference doc. (Engine Electronic Media Center): Media number LEBW4972 A&I guide for vibration Test Location Overall
1/2' 1
Engine front vertical (EFV) Engine front vertical (EFH) Engine rear vertical (ERV) Engine read horizontal (ERH) Generator rear vertical (GRV) Generator rear horizontal (GRH) Engine rear roll (ERR) Generator rear axle (GRA) Other Other
Record load factor when measurements are taken (full load recommended):
Record PF when measurements are taken (full load recommended): Note: Please attach any electronic vibration measurement results.
Notes:
1 1/2 2
2 1/2 3
Vibration Levels - 2 Vibration levels - use for all in-line 6 (e.g. C9, C15, C18, 3406, 3456C…) Built after 1/1/04. Reference ISO 8528-9
The dealer can obtain ISO standards from ISO or an authorized reseller such as ANSI, HIS, and Techstreet. Power kW
RMS overall values (2 Hz to 300 Hz)*
Engine speed *either measured or calculated direction of movement Measuring Point Number
s(mm)
v(mm)
a(m/s2)
s(mm)
a(m/s2)
s(mm)
v(mm/s)
1 2 3 4 5 6 7 8 ~ ~ Measuring Point Number
v(mm/s)
1 2 3 4 5 6 7 8 9 ~ ~ Number 1 2 3 4 5 6 7 8 9 ~ ~
a(m/s2)
3. Particulars of Measurement Equipment (optional for North America) Component Manufacturer Sensor Measuring Indicator Set Recording Instruments Calibration Apparatus
Note: Terms are according to ISO 2954. Mechanical Connection Measured Value Recorded Value Calibration Date
Measuring Range (Amplitude/Frequency)
Frequency Analyzer/Filter (Linear Range/Pass-Band) Recorded Value Calibration Date
Date for evaluation of measuring records (e.g. amplification, rate of feed)
Notes:
Type
Remarks
Save screen shots as JPGs to a folder, insert object from a file, choose JPG file Has all performance documentation been completed & saved for future reference?
Paste Final Configuration Screen Below:
Insert all Engine & EMPC Monitoring Screens Below
Yes No N/A
