3500 Start Up and Commissioning Checklist

7/29/2019 3500 Start Up and Commissioning Checklist

1/23

I ta l ic ized Items relate to Tier IV Comp l iance

Yes No N/A

Voltage:

Generator Model #:

Low Idle:

Timing:

Engine Arrangement #:

Engine Model Group:

Alt. Contact Name:

3500 Startup &

Commissioning Checkl ist

Genset Cover Sheet

SERVICE REPRESENTATIVE:

Selling Dealer: Service Request #:

Selling Dealer Address: City:

Service Engineer:

Zip Code:

Commissioning Date:

State/Province/Country:

Date of Service:

Customer Name:

Main Contact Name:

Telephone Number:

Generator Arrangement #:

Telephone Number:

Generator Serial #:

State/Province/Country: Zip Code:

City

Zip Code:

Generator Set Serial #:

LOCATION OF THE SYSTEM:

Street Address: City:

Service Dealer Address:

Project Name (if applicable):

High Idle:

Rated Speed:

State/Province/Country:

Type of installation:

PRODUCT INFORMATION

Engine Serial #:

SI units or Imperial

Frequency:

Amperage:

Rating:

Set Point Timing

Verfified:

Engine Derate:

Fuel Type:

Delegated final assembly

contract #:

Service Dealer (if

Different than Selling

Dealer):


2/23

Yes No N/A Yes No N/A

Yes No N/A Yes No N/A

All Configurations, Logic, Set Points and Programs Saved to Backup Media? Yes No N/A

1 Yes No N/A 10 Yes No N/A



4

5 Motor SKVA

6

7

8

9

UPS Manufacturer

UPS Model Number/Size

Enclosure Weather Tight

Proper Ventilation

Ambient Temperature:

Engine Room Temp:

Elevation:

Relative Humidity:

Load Diagram Created & Saved

ENVIROMENTAL CONDITIONS

Neutral Grounding Systems Unit connected in parallel

Generator Dried for 48Hours Before Start-up

(See SEHS9124):

Atmospheric Conditions:

STORAGE AND INSULATION

Visual Inspection Before

Start-up -- Grease, Water,Debris, (Foreign Material)

Drying Method:

Motor Total HP

Company Name:

INSTALLATION AND LOAD

COMMENTS AND RECOMMENDATIONS:

Full Load Data Created & Saved

Description of load

UPS Serial Number

Electrician Name: Telephone Number:

Please List all Lliterature that was Delivered and Reviewed:

SERVICE BULLETINS (List All Service Bulletins Addressed During this Visit):

Service Literature

As Built Drawings Delivered? Customer Acceptance Test:

INSTALLING ELECTRICIAN:


3/23

Customer Rep. Signature: Date:

Date:

Was Customer Offered ESC? Yes No N/A If no, why not?

1 Manufacturer:

2 Model number:

3 Serial number:

1 Yes No N/A5

Yes No N/A

2 Yes No N/A6

Yes No N/A


4 Yes No N/A

Customer Rep. Signature: Date:

Service Engineer Signature: Date:

All wires secure & check wire

terminations

Verify voltage/amperage

Verify phase rotation

Automatic Transfer Switch

Check for loose or missing

hardware

Service Engineer Signature:

CUSTOMER AUTHORIZATION TO SERVICE/TEST:

Job delays and problems:

SITE SPECIFICATIONS:

Start-up and commissioning is complete within factory standards.

CUSTOMER ACCEPTANCE:

Set all timers & exerciser Test for proper operation

Check for damage


4/23

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/A9 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 21

11 All safety shutdowns & warnings operational Yes No N/A

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 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.

Start-up

Note: Service Engineer must communicate with customer to understand site requirements for Personal Protective

Equipment (PPE), Lockout and other safety procedures.

Note: Ital ic ized Items relate to Tier IV Comp liance

1. Safety and Serviceability

Notes:

Notes:

2. Fuel System and Fuel Storage

Air supply system maintanance service intervals a

minium of 4500 hours (if engine manuafacturer

solution is not used)

Yes No N/A


5/23

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 (J1939 or lamp)

8 Over speed Yes No N/A 22 High exhaust system temperature

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 to operator (J1939 or lamp)

12 Over crank Yes No N/A 24"Regeneration System Disabled" communicated

13 Battery charger Yes No N/A to operator (J1939 or lamp)

14 Fire alarm Yes No N/A 25 Force/Disable Regneration control

15 Shutdown device Yes No N/A communicated to operator (J1939 or lamp)

1 Copy saved of the ECM replacement file or other

record governor settings saved

Yes No N/A 3 Is the engine installed as a constant or variable

speed engine

2 Was the engine ordered as a constant or variable

speed engine

3. Lube System

Notes:

4. Alarm Verification

Notes:

Notes:

5. Governor Settings


6/23

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

temperature (unmixed) (50o

C)

Yes No N/A

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

Notes:

6. Intake System/Exhaust System


7/23

1 Ball joint/slip joint/bellows properly installed Yes No N/A 23 Air compressor filter meet EPA requirements Yes No N/A

2 Installation must meet one of the following

requirements

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%

load 10o

C or less

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

8 Describe Dust Ejector connection location 32 DEF tank sample port installed Yes No N/A

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 -40o

C to

50o

C

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

7. Aftertreatment

*Aftertreatment section continued on next page


8/23

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

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

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 No N/A 7 Space heater operated 48 hours before start-up Yes No N/A

4 Space heater is off while engine is running Yes No N/A

Notes:

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

10 Check battery boosts / float controls Yes No N/A 20 Charging alternator belts properly inspected and

adjusted

Yes No N/A

Notes:

8. Jacket Water & Space Heater

9. Starter & Battery

Notes:

Yes No N/A


9/23

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

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

Yes No N/A

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/A3 Air shut-off is operational Yes No N/A 6 Motorized dampers are operational Yes No N/A

Notes:

Customer controlled fan: record ATAAC outlet

temperature when fan fully on at rated power

(50o

C maximum with 30o

C ambient). Adjust

resulting IMAT temperature for ambient test

conditions 1 for 1 back to the 30o

C ambient

reference.

10. Cooling System

11. Mechanical

Yes No N/A


10/23

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/A8 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:

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:

1 Check for loose or missing hardware Yes No N/A 2 Check crankshaft deflection / end play Yes No N/A

Notes:

13. Gen Syst - Control Panel

14. Gen Syst - Mechanical

12. Gen Syst - Electrical


11/23

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

Notes:

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:

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

Notes:

15. Gen Syst - Circuit Breakers

16. Gen Syst - Voltage Regulators

17. Automatic Transfer Switch


12/23

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/A7 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:

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:

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

Notes:

3. Fuel System and Fuel Storage

Reviewed start-up procedure & safety information

Commissioning

2. Maintenance and Coverage

1. Safety and Serviceability


13/23

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:

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

10 Crank termination systems Yes No N/A 20 Temperature detectors connected Yes No N/A

Notes:

1 Check intake and exhaust systems for leaks Yes No N/A 9 Emission level verif ied 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 instal led & operational Yes No N/A 12 Exhaust temperature (pre turbo) at ful l 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 No 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:

Notes:

4. Lube System

6. Intake System/Exhaust System

5. Alarm Verification


14/23

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

3 CEM temperature increase due to proximity of

external heat source

14 Low urea level warning in time to prevent shutdown Yes No N/A

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 -5o

C and 50o

C Yes No N/A

10 DEF tank temperature between -5o

C and 50o

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 22Air lines maintain temperature between -40o

C and

50o

C

Yes No N/A

Notes:

1 Space heater functioning properly Yes No N/A 3 Adjust thermostat JWH record setting Yes No N/A

2 Space heater operated 48 hours before start-up Yes No N/A 4 Record block temperature

Notes:

7. Aftertreatment

8. Jacket Water & Space Heater


15/23

1 Confirm auto start Yes No N/A 3 Charging alternator belts properly inspected and

adjusted

Yes No N/A

2 Charging alternator guards in place & secure Yes No N/A 4 Charge Rate (need data value):

Notes:

1 High water temperature shutdown Yes No N/A 6 Verify sufficient cooling provisions Yes No N/A

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 10 Differential Temperature Radiator (ref. to A&I

Notes:

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

Notes:

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

11. Mechanical

10. Cooling System

9. Starter & Battery


16/23

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

Notes:

1 Check for loose or missing hardware Yes No N/A

Notes:

1 Test any alarms / shunt trip Yes No N/A 4 Set circuit breaker trip unit for site conditions Yes No N/A

2 Check for tight connections Yes No N/A 5 Record circuit breaker settings:

3 Verify against generator Volts / Amps Yes No N/A

Notes:

14. Gen Syst - Mechanical

15. Gen Syst - Circuit Breakers

13. Gen Syst - Control Panel


17/23

Volts DC

Amps DC

Volts AC

Volts AC

Volts AC

Volts AC

Volts AC

Volts AC

Volts DC

Amps DC

Volts AC

Volts AC

Volts AC

Volts AC

Volts ACVolts AC

1 VR PID loop gains configured Yes No N/A 3 CDVR/ECM replacement file saved Yes No N/A

2 VR PID loop Gains recorded Yes No N/A

1 Verify voltage/amperage Yes No N/A 2 Verify phase rotation Yes No N/A

PMG output (2 to 3)

Notes:

NO LOAD

Exciter Field (F1,F2)


Sensing Line (T1,T2)

PMG output (1 to 2)

PMG output (1 to 3)

16. Gen Syst - Voltage Regulators

17. Automatic Transfer Switch

LOAD Record Values in boxes providedExciter Field (F1,F2)




Notes:


PMG output (1 to 2)

PMG output (1 to 3)

PMG output (2 to 3)




18/23

30 Second 30 Second

Insul. Test Reading Corrected

Beg. of

storage-MainStator

Beg.of

storage-Main

Rotor

Beg. of

storage-

Excitor Stator

Comments:

Beg. of

storage-

Excitor Rotor

Comments:

Beg. of

storage-PMG

Stator

30 Second 30 Second

Reading Corrected

Start-up-Main

Stator

Comments:

Start-up-Main

Rotor

Comments:

Start-up-

Excitor Stator

Comments:

*Insulation Test continued next page

Comments:

Winding Temp.

Winding Temp.

Comments:

1. Insulation Test

Winding Temp.

Reading Corrected

Comments:

Reference Doc. (Service Information System): SEHS9124

Winding Temp.

Reading Corrected

Winding Temp.

Winding Temp.

Click on media search, enter SEHS9124 in media number field

60 Second 60 Second

60 Second 60 Second

Start-up and Commissioning

Winding Temp.

Winding Temp.


19/23

Start-up-

Excitor Rotor

Comments:

Start-up-PMG

Stator

Comments:

Winding Temp.

Winding Temp.

Insulation Test Equipment Description:

Notes:


20/23

1

2

3

4

5

Test Location Overall 1/2' 1 1 1/2 2 2 1/2 3

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

Vibration Levels - 1

Order=(vibration frequency/engine RPM)

Vibration isolator serial number:

Vibration isolator model:

Vibration levels used for - use for all packages excluding in-line 6 (e.g. C9, C15, C18, 3406, 3456C) Built after 1/1/04Reference doc. (Engine Electronic Media Center): Media number LEBW4972 A&I guide for vibration

2. Vibration Levels

Vibration isolator manufacturer:

Vibration test equipment description - (Model, serial# & calibration date):

Record PF when measurements are taken (full load recommended):

Note: Please attach any electronic vibration measurement results.

Notes:

Record load factor when measurements are taken (full load recommended):


21/23

RMS overall values (2 Hz to 300 Hz)*

Engine speed

Measuring Point

Number s(mm)

1

2

3

4

5

6

7

8

~

~

Number v(mm/s)

1

2

3

4

5

6

7

8

9

~

~

Number a(m/s2)

1

2

3

4

5

6

7

8

9

~

~

*either measured or calculated direction of movement

Vibration levels - use for all in-line 6 (e.g. C9, C15, C18, 3406, 3456C) Built after 1/1/04.

Power kW

The dealer can obtain ISO standards from ISO or an authorized reseller such as ANSI, HIS, and Techstreet.

Reference ISO 8528-9

Vibration Levels - 2

v(mm) a(m/s2) s(mm)

Measuring Point

a(m/s2) s(mm) v(mm/s)


22/23

Type Remarks

3. Particulars of Measurement Equipment (optional for North America)

Component Manufacturer

Sensor

Calibration Apparatus

Note: Terms are according to ISO 2954.

Measuring Indicator Set

Recording Instruments

Recorded Value

Calibration Date

Mechanical Connection

Measured Value

Recorded Value

Calibration Date

Measuring Range (Amplitude/Frequency)

Frequency Analyzer/Filter (Linear Range/Pass-Band)

Notes:

Date for evaluation of measuring records (e.g. amplification, rate of

feed)


23/23

Yes No N/A

Insert all Engine & EMPC Monitoring Screens Below

Save screen shots as JPGs to a folder, insert object from a file, choose JPG file

Paste Final Configuration Screen Below:

Has all performance documentation been completed & saved for future reference?

3500 Start Up and Commissioning Checklist

Documents