3500 Startup & Commissioning Checklist Genset Cover Sheet

Italicized Items relate to Tier IV Compliance

SERVICE REPRESENTATIVE: Selling Dealer: Service Engineer: Selling Dealer Address: State/Province/Country: Date of Service: Commissioning Date: Service Dealer (if Different than Selling Dealer): Service Dealer Address: State/Province/Country: LOCATION OF THE SYSTEM: Customer Name: Street Address: State/Province/Country: Main Contact Name: Alt. Contact Name: PRODUCT INFORMATION Engine Serial #: Engine Arrangement #: Engine Model Group: Type of installation: Rated Speed: Low Idle: High Idle: Timing: Set Point Timing Verfified: Engine Derate: SI units or Imperial Generator Set Serial #: Generator Serial #: Generator Arrangement #: Generator Model #: Voltage: Frequency: Amperage: Rating: Project Name (if applicable): City: Zip Code: Telephone Number: Telephone Number: City Zip Code: City: Zip Code: Service Request #:

Yes No N/A

Fuel Type: Delegated final assembly contract #:

ENVIROMENTAL CONDITIONS Ambient Temperature: Engine Room Temp: Atmospheric Conditions: STORAGE AND INSULATION Generator Dried for 48 Hours Before Start-up (See SEHS9124): Drying Method: Visual Inspection Before Start-up -- Grease, Water, Debris, (Foreign Material) Yes No N/A Yes No N/A Elevation: Relative Humidity:

INSTALLING ELECTRICIAN: Company Name: Electrician Name: Telephone Number:

Service Literature As Built Drawings Delivered? Yes No N/A Customer Acceptance Test: Yes No N/A Yes No N/A

All Configurations, Logic, Set Points and Programs Saved to Backup Media? Please List all Lliterature that was Delivered and Reviewed:

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

INSTALLATION AND LOAD 1 Neutral Grounding Systems 2 Enclosure Weather Tight 3 Proper Ventilation 4 Description of load 5 Motor SKVA 6 Motor Total HP 7 UPS Manufacturer 8 UPS Model Number/Size 9 UPS Serial Number COMMENTS AND RECOMMENDATIONS:
Yes No N/A Yes No N/A Yes No N/A

10 Unit connected in parallel 11 Load Diagram Created & Saved 12 Full Load Data Created & Saved

Yes No N/A Yes No N/A Yes No N/A

CUSTOMER AUTHORIZATION TO SERVICE/TEST: Customer Rep. Signature: Service Engineer Signature: Date: 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: 5 Yes No N/A 6 Yes No N/A Yes No N/A Yes No N/A Check for loose or missing hardware All wires secure & check wire terminations

1 Verify voltage/amperage

Yes No N/A

2 Verify phase rotation 3 Set all timers & exerciser 4 Check for damage

Yes No N/A Yes No N/A

7 Test for proper operation

CUSTOMER ACCEPTANCE: Start-up and commissioning is complete within factory standards. Customer Rep. Signature: Service Engineer Signature: Date: Date:

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 Compliance

Start-up
1. Safety and Serviceability
1 Genset is free of damage 2 Hot pipes are wrapped 3 All hoses, piping & wiring is/are secure 4 Spillage containment acceptable 5 Personal protection equipment worn 6 Floors are clean no hazards 7 Floor openings are covered 8 Genset is level with all holding bolts secure 9 Warning decals & plates are installed 10 All guards and heat shields are in place 11 All safety shutdowns & warnings operational Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 12 Fire extinguisher present & charged 13 Fire suppression unlocked & operational 14 Pipe work & services are color coded/labeled 15 Remote start/stop checked & operational 16 Emergency stop functional 17 Sight glasses are visible 18 Gauges are functional (oil, fuel, air, other) 19 Proper grounding (refer to REHS4634) 20 Air intake free of airborne debris 21 Air supply system maintanance service intervals a minium of 4500 hours (if engine manuafacturer solution is not used) Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

2. Fuel System and Fuel Storage

1 Properly sized fuel lines 2 Fuel transfer pump properly installed 3 Tank fuel level is verified 4 Fuel tank mounting is level 5 Fuel filter primed 6 Fuel filter not damaged 7 Properly vented fuel tanks 8 Fuel tank plugs properly installed 9 Off package fuel lines are proper material 10 Foot valve installed & operational 11 Correct valve installed in the return Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 12 Check for fuel leaks 13 Critical fuel level shutdown 14 Proper operation of fuel tank alarms 15 High fuel level gauge stops pump 16 Properly connected fuel return/overflow lines 17 Fuel cooler installed (external) 18 Shutoff valves are operating properly 19 Solenoid valve operating properly 20 Using bio-diesel 21 If so, what percent 22 ULSD sticker on all fuel filling points Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

3. Lube System
1 Jacket oil heater operational 2 Oil sample taken (SOS) 3 Oil level is correct 4 Pipes routed through front end of base 5 Remove crankcase covers, plugs & tape 6 Install crankcase breather hose if necessary; check for proper installation & routing 7 Oil make-up system installed Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 8 Check for leaks 9 Oil pressures within specifications 10 Oil meets specifications 11 Pre-lubrication system installed 12 Check pre-lube installation 13 CAT DEO-ULS/ API CJ 4 oil sticker on all engine lube filling points 14 Oil renewal system present Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

4. Alarm Verification
1 Low water level 2 High water temperature 3 Low water temperature 4 Low oil pressure 5 Low oil level 6 Low fuel level 7 High fuel level 8 Over speed 9 E-Stop 10 Crank termination systems 11 Low DC Voltage 12 Over crank 13 Battery charger 14 Fire alarm 15 Shutdown device Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 16 High air inlet manifold temperature 17 High / low battery voltage 18 Jacket water pressure 19 Rupture basin 20 Temperature detectors connected 21 Engine warning lamp communicated to operator (J1939 or lamp) 22 High exhaust system temperature communicated to operator (J1939 or lamp) 23 Diesel particulate filter warning communicated 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) Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

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

Notes:

6. Intake System/Exhaust System

1 Check for damage 2 Remove air filter bags / covers 3 Air filter gasket serviceable / accessible 4 Check exhaust cowl & rain cap 5 Check exhaust water drain pipe work & valves 6 Condensate drain provided 7 Air filter housing seal present & serviceable 8 Check for missing or loose hardware 9 Pre-lube turbo charger 10 Drain valves fitted relative to exhaust system 11 Exhaust directed away from building / personnel 12 Acceptable size of supply air - intake 13 Check intake air systems (sized properly per A&I specifications) 14 Check intake and exhaust systems for leaks 15 Check for duct isolation 16 Emissions control unit installed & operational 17 Exhaust pipe properly supported 18 Flexible exhaust fitting to isolate vibrations and allow for thermal expansion 19 Maximum air inlet restriction at turbo compressor inlet - clean filter (3.7kPa) 20 Air inlet restriction indicator setting (6.2kPa) Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 24 Exhaust backpressure at turbo outlet 25 Use of engine manufacturer Supplied Flex Kit for engine exhaust - if yes record part # 26 Use of engine manufacturer Supplied Flex Kit for aftertreatment inlet - if yes record part # 27 Use of engine manufacturer Supplied Flex Kit for aftertreatment outlet - if yes record part # 28 If no, you must have written document of engine manufacturer's approval. Record flex kit description here or in the Notes space below 29 Exhaust wrapping about flex joint approved 30 Verify pipe material (16 gage) and thickness (1.5 4 mm) for turbo to CEM connection 31 Charge air cooling system 100% manufacturer supplied and factory installed, and free of obstructions to external cooling flow 32 Charge air cooler restriction test (15kPa) 33 Charge air cooler capability test, ATAAC outlet temperature (unmixed) (50 o C) 34 Verify urea (monitoring level and storage) matches TMI specifications 35 Verify air pressure supply is with 60-120 psi, and maximum allowable pressure drop from air source to injector nozzle is not exceeded 36 DEF liquid pressure at inlet to dosing cabinet is within range 2-5 psi at full load operation 37 All emissions labels visible - record location(s) below if not visible Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 21 Rise over ambient to engine air inlet temp sensor (5C maximum) 22 Inlet temperature sensor in the inlet flow path 23 If no, describe location Yes No N/A Yes No N/A

Yes No N/A Yes No N/A

Yes No N/A Yes No N/A

Notes:

7. Aftertreatment
1 Ball joint/slip joint/bellows properly installed 2 Installation must meet one of the following requirements a) Turbo to CEM inlet exhaust pipe length 366 cm or less b) Turbo to CEM inlet temperature drop @ 10% load 10 o C or less 3 Turbo to CEM pipe fully insulated 4 CEM oriented parallel to horizon +/- 5 degrees 5 Turbo outlet to CEM inlet temperature drop at full load 6 Communicate that top of CEM is not suitable for a work platform 7 Dust Ejector connected after the CEM 8 Describe Dust Ejector connection location 9 Dosing cabinet a maximum of 20 feet (6m) from CEM 10 Top of dosing cabinet at or below bottom of CEM mounting pads 11 Dosing cabinet a maximum of 100 feet (30m) from engine 12 Dosing cabinet ambient temperature -40 o C to 50 o C 13 Dosing cabinet mounted not more than 18 degrees from vertical 14 Area around dosing cabinet unobstructed Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 23 Air compressor filter meet EPA requirements 24 Air compressor meet demand of dosing module 25 Air compressor lines properly sized and have no P traps 26 Engine mounted air compressor supply pre-boosted (only pre-boosted is allowed) 27 DEF tank material meet requiremetns in A&I Guide 28 DEF filter meet requiremetns in A&I Guide 29 Ratio of 1 fuel tank refill to 1 DEF tank refill for systems with a constantly visible DEF level indicator 30 Ratio of 2 fuel tank refills to 1 DEF tank refill for systems without a constantly visible DEF level indicator 31 DEF tank protected against frozen urea blocking passage 32 DEF tank sample port installed 33 Exhaust connected properly 34 Exhaust weight transfer to CEM meets A&I specification 35 Engine to CEM inlet connection 400 Nm 36 CEM to atmosphere connection 100 Nm 37 Customer supplied wiring harness properly routed 38 Customer supplied wiring harness not kinked, mounted away fro mheat sources, properly supported, and marked as not a step 39 Customer supplied wiring harness meets the wire specifications for material and length as specified in the wiring diagram 40 Customer supplied wiring harness matches the pin out as specified in the wiring diagram 41 Dosing cabinet to CEM urea lines routed properly 42 Dosing cabinet to CEM urea lines not kinked, mounted away from heat sources, properly supported, and marked as not a step 43 Main tank to dosing cabinet urea lines routed properly 44 Main tank to dosing cabinet urea lines material meets specifications in A&I Guide 45 Urea lines meet urea pump requirement for line restriction 46 Urea lines connected properly Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Yes No N/A

Yes No N/A

Yes No N/A

Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

15 Dosing cabinet air connection as specified in A&I Guide 16 Dosing cabinet air connection location as specified in A&I Guide 17 Dosing cabinet vent line routed to storage tank or approved drain 18 Dosing cabinet vent line exit below injector height

Yes No N/A

Yes No N/A

Yes No N/A Yes No N/A Yes No N/A

Yes No N/A Yes No N/A Yes No N/A

19 No low spots in dosing cabinet vent line 20 Urea quality meets ISO22241-1 21 Dosing cabinet AC supply meets requirements in A&I Guide 22 Dosing cabinet DC supply meets requirements in A&I Guide *Aftertreatment section continued on next page

Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Yes No N/A Yes No N/A Yes No N/A Yes No N/A

47 Air lines maintain the air quality as specified in the A&I Guide 48 Air lines routed and mounted properly 49 Air lines connected properly 50 Air compressor appropriate for environment

Yes No N/A Yes No N/A Yes No N/A Yes No N/A

51 Dosing cabinet air supply meet air quality requirements in A&I Guide 52 Air lines not kinked, mounted away from heat sources, properly supported, and marked as not a step

Yes No N/A Yes No N/A

Notes:

8. Jacket Water & Space Heater

1 Jacket water heater wiring and voltage correct 2 Jacket water heater bleed off air required 3 Verify JWH valve position is open during usage 4 Space heater is off while engine is running Yes No N/A Yes No N/A Yes No N/A Yes No N/A 5 Space heater thermostat is installed 6 Space heater functioning properly 7 Space heater operated 48 hours before start-up Yes No N/A Yes No N/A Yes No N/A

Notes:

9. Starter & Battery

1 Confirm auto start 2 Inspect starter wiring 3 Starter operational check 4 Cycle crank timer 5 Check oil lubrication 6 Air/hydraulic compressor operational 7 Isolation valves correctly positioned 8 Condensate drain provided 9 Check high & low air / hydraulic pressure 10 Check battery boosts / float controls Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 11 Battery charging alternator operational check 12 Batteries connected properly 13 Batteries isolated from floor 14 Batteries charged (deep cycle) before use 15 Battery cables & racks properly installed 16 Proper electrolyte level & proper specific gravity 17 Proper system voltage 18 Trickle charger 19 Charging alternator guards in place & secure 20 Charging alternator belts properly inspected and adjusted Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

10. Cooling System

1 Check for leaks 2 Check coolant level 3 Check for damage & unusual noise 4 Filler cap & seal installed properly 5 Check antifreeze (refer to A&I Guide) 6 Isolation valves & drain valves installed Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 10 High water temperature shutdown 11 Expansion tank highest level 12 All guards & shrouds installed with proper 13 clearance Discharge air unobstructed 14 Cooling fan control strategy documented and verified 15 Customer controlled fan: record ATAAC outlet temperature when fan fully on at rated power (50 o C maximum with 30 o C ambient). Adjust resulting IMAT temperature for ambient test conditions 1 for 1 back to the 30 o C ambient reference. 16 Customer controlled fan: record jacket water outlet temp when fan fully on 17 Verify sufficient cooling/air flow provisions per A&I guide Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

7 Drain valves routed correctly

Yes No N/A

8 Correct condition, alignment, and tension of fan belts / pulleys 9 Auxiliary supply voltage to fans correct

Yes No N/A Yes No N/A

Notes:

11. Mechanical
1 Package properly mounted 2 Package supports & vibration isolators installed 3 Air shut-off is operational Yes No N/A Yes No N/A Yes No N/A 4 Over speed shut-down is correct 5 Over-crank shut-down is correct 6 Motorized dampers are operational Yes No N/A Yes No N/A Yes No N/A

Notes:

12. Gen Syst - Electrical

1 Check AC & DC electrical 2 Check for loose wiring & secure 3 Verify phase sequence of wiring 4 Confirm stator RTD's are functional 5 Annunciators installed & wiring is complete 6 Electrical bonding of services is complete 7 Interconnects complete & ready for load test 8 Connections completed to transfer switch 9 Fuse & fuse ratings are verified Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 10 Over voltage protection 11 Over current protection 12 Check diodes 13 Correct generator wiring configuration 14 Unit is properly grounded (REHS4632) 15 Adjust voltage 16 All covers are in position 17 Adjust frequency 18 Complete generator alignment process Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

13. Gen Syst - Control Panel

1 Secure all wires 2 Check all wire terminations for tightness 3 Energize set & system controls 4 Verify operation of annunciator 5 Check auto / manual stop operation 6 Check generator local controls 7 Check generator remote controls 8 Verify interconnect wiring Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 9 Check generator system controls 10 Verify settings (correct as needed) 11 Check software & upload latest version 12 Check condition / operation of meters 13 Remote emergency stop wired / functional 14 Calibrations are checked 15 Select set parameters on system (ECM
download)

Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

14. Gen Syst - Mechanical

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

Notes:

15. Gen Syst - Circuit Breakers

1 Test any alarms / shunt trip 2 Check for tight connections Yes No N/A Yes No N/A 3 Verify against generator Volts / Amps 4 Set circuit breaker trip unit for site conditions Yes No N/A Yes No N/A

Notes:

16. Gen Syst - Voltage Regulators

1 All settings verified 2 Check cross current compensation circuit 3 Check voltage power factor regulation Yes No N/A Yes No N/A Yes No N/A 4 Install latest software version 5 VR PID loop gains configured and recorded Yes No N/A Yes No N/A

Notes:

17. Automatic Transfer Switch

1 Check for damage 2 Check for loose or missing hardware 3 All wires secure & check wire terminations 4 Test for proper operation Yes No N/A Yes No N/A Yes No N/A Yes No N/A 5 Verify voltage/amperage 6 Set all timers & exerciser 7 Verify phase rotation Yes No N/A Yes No N/A Yes No N/A

Notes:

Commissioning
1. Safety and Serviceability
1 Personal protection equipment worn 2 Floors are clean no hazards 3 Floor openings are covered 4 Genset is level with all holding bolts secure 5 Warning decals & plates are installed 6 All guards and heat shields are in place 7 All safety shutdowns & warnings operational 8 Fire extinguisher present & charged 9 Fire suppression unlocked & operational 10 Pipe work & services are color coded/labeled 11 Remote start/stop checked & operational 12 Emergency stop functional 13 sight glasses are visible Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 14 Gauges are functional (oil, fuel, air, other) 15 Proper grounding (refer to REHS4634) 16 Air intake free of airborne debris 17 Access routes unobstructed 18 Overhead obstructions are clearly marked 19 Overhead & side clearance is acceptable 20 Adequate access to fluid fill areas to prevent spills 21 Air/oil/fuel filters are accessible 22 Level indicators are accessible 23 Key components are labeled 24 Engine room noise level policy satisfied 25 No unauthorized access Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

2. Maintenance and Coverage

Reviewed start-up procedure & safety information

1 Reviewed OMM, Parts Manual, Warranty, SOS & service needs 2 CSA was offered to the customer 3 CSA was accepted by the customer 4 ESC was offered to the customer 5 ESC was accepted by the customer Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 6 Copy of ESC form saved in dealer records 7 Has operator / maintenance supervisor been trained on engine operation and maintenance 8 Special requirements & testing 9 Additional parts purchased or ordered

Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

3. Fuel System and Fuel Storage

1 Check for fuel leaks 2 Critical fuel level shutdown 3 Proper operation of fuel tank alarms 4 Properly connected fuel return/overflow lines 5 Shutoff valves are operating properly Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 6 Solenoid valve operating properly 7 High fuel level gauge stops pump 8 Fuel system schematic created/saved 9 Fuel pressure matches TMI specification Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

4. Lube System
1 Oil level is correct 2 Check for leaks Yes No N/A Yes No N/A 3 Oil pressures within specifications 4 Oil meets specifications Yes No N/A Yes No N/A

Notes:

5. Alarm Verification
1 Low water level 2 High water temperature 3 Low water temperature 4 Low oil pressure 5 Low oil level 6 Low fuel level 7 High fuel level 8 Over speed 9 E-Stop 10 Crank termination systems Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 11 Low DC Voltage 12 Over crank 13 Battery charger 14 Fire alarm 15 Shutdown device 16 High air inlet manifold temperature 17 High / low battery voltage 18 Jacket water pressure 19 Rupture basin 20 Temperature detectors connected Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

Notes:

6. Intake System/Exhaust System

1 Check intake and exhaust systems for leaks 2 Check intake air systems (sized properly per A&I specifications) 3 Check for duct isolation 4 Emissions control unit installed & operational 5 Flexible exhaust fitting to isolate vibrations and allow for thermal expansion 6 Create / save air supply / exhaust layout 7 Ensure proper exhaust system back pressure per specifications 8 Exhaust leg pressure differential less than 1kPa Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 9 Emission level verified within specifications 10 Record boost (inlet manifold) pressure: 11 Record temperature after cooler: 12 Exhaust temperature (pre turbo) at full load: 13 Exhaust port temperatures at full load 14 Record air filter differential pressure: 15 Record exhaust temperature stack: 16 Record intake manifold air temperature: Yes No N/A

Notes:

7. Aftertreatment
1 Following initial start-up procedure from Appendix B in the A&I guide 2 Back pressure differential before CEM 1kPA 3 CEM temperature increase due to proximity of external heat source 4 Maximum 1L water accumulation at 5 degree tilt Yes No N/A Yes No N/A Yes No N/A 12 DEF tank venting meet fumes leak requirements 13 DEF tank venting routed to meet local and OSHA guidelines for ammonia fumes 14 Low urea level warning in time to prevent shutdown 15 If exhaust connection supplied by Caterpillar, see TMI for value and include in customer allowance (Not to exceed 6kPa) 16 If exhaust connection supplied by customer, measure and include in customer allowance (Not to exceed 6kPa) 17 Engine to CEM temperature drop does not exceed maximum figure in A&I Guide 18 Maximum 6 kPa difference from CEM to atomospheric pressure 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) 20 Urea lines temperature between -5 o C and 50 o C 21 Air lines allow dosing pressure and flow rate specified in A&I Guide 22 Air lines maintain temperature between -40 o C and 50 o C Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A

5 Dosing cabinet air pressure/air flow at customer supplied compressor as listed in A&I Guide 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 7 Dosing Cabinet air supply a minimum of 105 psi (724 kPa) within 3 minutes 8 Compressor capable of delivering 10 cfm for 30 seconds and still maintain a tank pressure gretaer than 80 psi (550 kPa) 9 Dosing cabinet air supply capable of 0-10 SCFM 10 DEF tank temperature between -5 o C and 50 o C 11 DEF tank venting affect head pressure

Yes No N/A

Yes No N/A Yes No N/A Yes No N/A

Yes No N/A Yes No N/A Yes No N/A

Yes No N/A Yes No N/A Yes No N/A

Notes:

8. Jacket Water & Space Heater

1 Space heater functioning properly 2 Space heater operated 48 hours before start-up Yes No N/A Yes No N/A 3 Adjust thermostat JWH record setting 4 Record block temperature Yes No N/A

Notes:

9. Starter & Battery

1 Confirm auto start 2 Charging alternator guards in place & secure Yes No N/A Yes No N/A 3 Charging alternator belts properly inspected and adjusted 4 Charge Rate (need data value): Yes No N/A

Notes:

10. Cooling System

1 High water temperature shutdown 2 Expansion tank highest level 3 All guards & shrouds installed with proper clearance 4 Discharge air unobstructed 5 Hot air recirculation prevented Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 6 Verify sufficient cooling provisions 7 Coolant mixing ratios 8 Jacket water heater supply (Volts / Amps) 9 Pressure test (record PSI) 10 Differential Temperature Radiator (ref. to A&I Guide) Yes No N/A

Notes:

11. Mechanical
1 Air shut-off is operational 2 Over speed shut-down is correct 3 Over-crank shut-down is correct Yes No N/A Yes No N/A Yes No N/A 4 Motorized dampers are operational 5 Inspect package supports and vibration isolators 6 Inspect package for proper mounting Yes No N/A Yes No N/A Yes No N/A

Notes:

12. Gen Syst - Electrical

1 Unit is properly grounded (REHS4632) 2 Adjust voltage Yes No N/A Yes No N/A 3 All covers are in position 4 Adjust frequency Yes No N/A Yes No N/A

Notes:

13. Gen Syst - Control Panel

1 Verify settings (correct as needed) 2 Check software & upload latest version 3 Check condition / operation of meters Yes No N/A Yes No N/A Yes No N/A 4 Remote emergency stop wired / functional 5 Calibrations are checked 6 Select set parameters on system (ECM download) Yes No N/A 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

1 Test any alarms / shunt trip 2 Check for tight connections 3 Verify against generator Volts / Amps Yes No N/A Yes No N/A Yes No N/A 4 Set circuit breaker trip unit for site conditions 5 Record circuit breaker settings: Yes No N/A

Notes:

16. Gen Syst - Voltage Regulators LOAD

Exciter Field (F1,F2) Exciter Field (F1,F2) Sensing Line (T1,T2) Sensing Line (T1,T3) Sensing Line (T2,T3) PMG output (1 to 2) PMG output (1 to 3) PMG output (2 to 3) Volts DC Amps DC Volts AC Volts AC Volts AC Volts AC Volts AC Volts AC

Record Values in boxes provided

NO LOAD
Exciter Field (F1,F2) Exciter Field (F1,F2) Sensing Line (T1,T2) Sensing Line (T1,T3) Sensing Line (T2,T3) PMG output (1 to 2) PMG output (1 to 3) PMG output (2 to 3) Volts DC Amps DC Volts AC Volts AC Volts AC Volts AC Volts AC Volts AC

1 VR PID loop gains configured 2 VR PID loop Gains recorded

Yes No N/A Yes No N/A

3 CDVR/ECM replacement file saved

Yes No N/A

Notes:

17. Automatic Transfer Switch

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

Notes:

Start-up and Commissioning

1. Insulation Test
Reference Doc. (Service Information System): SEHS9124 Click on media search, enter SEHS9124 in media number field 30 Second Insul. Test 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: 30 Second Reading 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 60 Second Reading 30 Second Corrected 60 Second Corrected Reading 60 Second Reading 30 Second Corrected 60 Second Corrected

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 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. 1/2' 1
1 1/2 2 2 1/2 3

Notes:

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 1 2 3 4 5 6 7 8 ~ ~ Measuring Point Number 1 2 3 4 5 6 7 8 9 ~ ~ Number 1 2 3 4 5 6 7 8 9 ~ ~ a(m/s2) v(mm/s) a(m/s2) s(mm) v(mm/s) s(mm) v(mm) a(m/s2) s(mm)

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

Component Manufacturer Sensor Measuring Indicator Set Recording Instruments Calibration Apparatus Type Remarks

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:

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? Yes No N/A

Paste Final Configuration Screen Below:

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