Cat Compact Genset

Startup & Commissioning

Checklist Cover Sheet
Bold Italicized Items relate to Tier IV Compliance

SERVICE REPRESENTATIVE:
Selling Dealer:

Service Request #:

Service Engineer:
Selling Dealer Address:

City:

State/Province/Country:

Zip Code:

Date of Service:
Commissioning Date:
Servicing Dealer (if
Different than Selling
Dlr):
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:

Rating:

Set Point Timing

Verfified:
Engine Derate:

Yes No N/A

Fuel Type:
Delegated final assembly
contract #:

ENVIROMENTAL CONDITIONS
Ambient Temperature:

Elevation:

Engine Room Temp:

Atmospheric
Conditions:

Relative Humidity:

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:
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 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 Motor 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

5 Check for loose or missing

hardware

Yes No N/A

2 Verify phase rotation

Yes No N/A

6 All wires secure & check wire

terminations

Yes No N/A

3 Set all timers & exerciser

Yes No N/A

7 Test for proper operation

Yes No N/A

4 Check for damage

Yes No N/A

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

Date:

Service Engineer Signature:

Date:

CATERPILLAR COMPACT 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.

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

21 Regeneration System Disable operator switch

communication (ISO symbol recommended)

Yes No N/A

11 All safety shutdowns & warnings operational

Yes No N/A

Notes:

2. Fuel System and Fuel Storage

1 Properly sized fuel lines

Yes No N/A

10 Foot valve installed & operational

Yes No N/A

2 Fuel transfer pump properly installed

Yes No N/A

11 Correct valve installed in the return

Yes No N/A

3 Tank fuel level is verified

Yes No N/A

12 Check for fuel leaks

Yes No N/A

4 Fuel tank mounting is level

Yes No N/A

13 Critical fuel level shutdown

Yes No N/A

5 Fuel filter primed

Yes No N/A

14 Proper operation of fuel tank alarms

Yes No N/A

6 Fuel filter not damaged

Yes No N/A

15 Properly connected fuel return/overflow lines

Yes No N/A

7 Properly vented fuel tanks

Yes No N/A

16 Shutoff valves are operating properly

Yes No N/A

8 Fuel tank plugs properly installed

Yes No N/A

17 Solenoid valve operating properly

Yes No N/A

9 Off package fuel lines are proper material

Yes No N/A

18 ULSD sticker on all fuel filling points

Yes No N/A

Notes:

3. Lube System
1 Jacket oil heater operational

Yes No N/A

6 Oil level is correct

Yes No N/A

2 Oil sample taken (SOS)

Yes No N/A

7 Check for leaks

Yes No N/A

3 Install crankcase breather hose if necessary

Yes No N/A

8 Oil pressures within specifications

Yes No N/A

4 Pipes routed through front end of base

Yes No N/A

9 Oil meets specifications

Yes No N/A

5 Remove crankcase covers, plugs & tape

Yes No N/A

10 CAT DEO-ULS/ API CJ 4 oil sticker on all engine

lube filling points

Yes No N/A

1 Low water level

Yes No N/A

12 Over crank

Yes No N/A

2 High water temperature

Yes No N/A

13 Battery charger

Yes No N/A

3 Low water temperature

Yes No N/A

14 Fire alarm

Yes No N/A

4 Low oil pressure

Yes No N/A

15 Shutdown device

Yes No N/A

5 Low oil level

Yes No N/A

16 High air inlet manifold temperature

Yes No N/A

6 Low fuel level

Yes No N/A

17 High / low battery voltage

Yes No N/A

7 High fuel level

Yes No N/A

18 Jacket water pressure

Yes No N/A

8 Over speed

Yes No N/A

19 Rupture basin

Yes No N/A

9 E-Stop

Yes No N/A

20 Temperature detectors connected

Yes No N/A

10 Crank termination systems

Yes No N/A

21 Engine warning lamp operator communication

(J1939 or lamp)

Yes No N/A

11 Low DC Voltage

Yes No N/A

Notes:

4. Alarm Verification

Notes:

5. Governor Settings
1 Copy saved of the ECM replacement file or
other record governor settings saved

Notes:

Yes No N/A

6. Intake System/Exhaust System

1 Check for damage

Yes No N/A

19 Air inlet restriction indicator setting (7.5kPa)

Yes No N/A

2 Remove air filter bags / covers

Yes No N/A

Yes No N/A

3 Air filter gasket serviceable

Yes No N/A

20 Rise over ambient to engine air inlet temp sensor

maximum)
21 (40C
Exhaust
backpressure (within range 2-10kPa)

4 Check exhaust cowl & rain cap

Yes No N/A

22 Use of acceptable Flex Kit -record part# below

Yes No N/A

5 Check exhaust water drain pipe work & valves

Yes No N/A

6 Condensate drain provided

Yes No N/A

23 Exhaust wrapping about flex joint approved

Yes No N/A

7 Air filter housing seal present & serviceable

Yes No N/A

Yes No N/A

8 Check for missing or loose hardware

Yes No N/A

24 Verify stainless steel pipe material (16 gage) and

(1.5connected
mm) for turbo
CEM connection
25 thickness
Dust ejector
after to
CEM

9 Pre-lube turbo charger

Yes No N/A

26 Charge air cooler restriction test (12kPa)

Yes No N/A

10 Drain valves fitted relative to exhaust system

Yes No N/A

Yes No N/A

11 Exhaust directed away from building / personnel

Yes No N/A

27 Charge air cooler capability test, ATAAC outlet

(unmixed) level
(50C)and storage) matches
28 temperature
Verify urea (monitoring
TMI
Verifyspecifications
air pressure supply is with 60-120 psi, and
maximum
air source
DEF liqduidallowable
pressurepressure
at inlet todrop
SCRfrom
injection
to
injector
nozzle
is
not
exceeded
nozzle
is within
full load
Air pressure
lossrange
from 1-5psi
dosingatcabinet
to operation
SCR inlet
nozzle
does
not
exceed
10psi
at
full
load
Verify urea (monitoring level and storage)operation
matches

Yes No N/A

Yes No N/A

Yes No N/A

Yes No N/A

12 Acceptable size of supply air

Yes No N/A

29

13 Check intake and exhaust systems for leaks

Yes No N/A

30

14 Check intake air systems

Yes No N/A

31

15 Emissions control unit installed & operational

Yes No N/A

32

16 Exhaust pipe properly supported

Yes No N/A

Yes No N/A

17 Flexible exhaust fitting to isolate vibrations and

for thermal
18 allow
Maximum
air inletexpansion
resitriction to turbo compressor -

Yes No N/A

specifications
33 TMI
All emissions
labels visible - record location if not
visible
34 High exhaust system temperature operator
(ISO
recommended)
35 communication
Diesel particulate
filtersymbol
warning
operator
communication (ISO symbol recommended)

Yes No N/A

Yes No N/A

clean filter (3.7kPa)

Notes:

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

7. 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 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:

8. Starter & Battery

1 Inspect starter wiring

Yes No N/A

9 Battery cables & racks properly installed

Yes No N/A

2 Starter operational check

Yes No N/A

10 Proper electrolyte level & proper specific gravity

Yes No N/A

3 Cycle crank timer

Yes No N/A

11 Proper system voltage

Yes No N/A

4 Check battery boosts / float controls

Yes No N/A

12 Trickle charger

Yes No N/A

5 Battery charging alternator operational check

Yes No N/A

13 Confirm auto start

Yes No N/A

6 Batteries connected properly

Yes No N/A

14 Charging alternator guards in place & secure

Yes No N/A

7 Batteries isolated from floor

Yes No N/A

15 Charging alternator belts properly inspected and

adjusted

Yes No N/A

8 Batteries charged (deep cycle) before use

Yes No N/A

Notes:

9. Cooling System (Jacket Water and SCAC Systems)

1 Check for leaks

Yes No N/A

9 High water temperature shutdown

Yes No N/A

2 Check coolant level

Yes No N/A

10 Expansion tank highest level

Yes No N/A

3 Check for damage & unusual noise

Yes No N/A

Yes No N/A

4 Filler cap & seal installed properly

Yes No N/A

11 All guards & shrouds installed with proper

clearance
12 Discharge air unobstructed

5 Check antifreeze (refer to A&I Guide)

Yes No N/A

Yes No N/A

6 Isolation valves & drain valves installed

Yes No N/A

14 Cooling fan control strategy documented and

verified
15 Customer controlled fan: record ATAAC outlet
temperature when fan fully on (50 C minimum)

7 Drain valves routed correctly

Yes No N/A

16 Customer controlled fan: record jacket water outlet

temp when fan fully on

Yes No N/A

8 Correct condition, alignment, and tension of fan

belts / pulleys

Yes No N/A

17 Verify suggicient cooling/air flow provisions per A&I

guide

Yes No N/A

Yes No N/A
Yes No N/A

Notes:

10. Mechanical
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

Notes:

11. 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

Notes:

12. 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 download)

Yes No N/A

8 Verify interconnect wiring

Yes No N/A

Notes:

13. Gen Syst - Mechanical

1 Check for loose or missing hardware

Notes:

Yes No N/A

14. 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:

15. Gen Syst - Voltage Regulators

Notes:

16. Automatic Transfer Switch

1 Set all timers & exerciser

Yes No N/A

5 Test for proper operation

Yes No N/A

2 Check for damage

Yes No N/A

6 Verify voltage/amperage

Yes No N/A

3 Check for loose or missing hardware

Yes No N/A

7 Verify phase rotation

Yes No N/A

4 All wires secure & check wire terminations

Yes No N/A

Notes:

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

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

1 Check for fuel leaks

Yes No N/A

4 Properly connected fuel return/overflow lines

Yes No N/A

2 Critical fuel level shutdown

Yes No N/A

5 Shutoff valves are operating properly

Yes No N/A

3 Proper operation of fuel tank alarms

Yes No N/A

6 Solenoid valve operating properly

Yes No N/A

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:

4. Lube System

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

10 Crank termination systems

Notes:

6. Governor Settings
1 Copy of the ECM replacement file or record of
other governor settings saved

Yes No N/A

Notes:

7. Intake System/Exhaust System

1 Check intake and exhaust systems for leaks

Yes No N/A

8 Record boost (inlet manifold) pressure:

Yes No N/A

2 Check intake air systems (sized properly per A&I

specifications)

Yes No N/A

9 Ensure proper exhaust system back pressure per

specifications"

Yes No N/A

3 Emissions control unit installed & operational

Yes No N/A

10 Record temperature after cooler:

Yes No N/A

4 Exhaust pipe properly supported

Yes No N/A

11 Exhaust temperature (pre turbo) at full load:

Yes No N/A

5 Flexible exhaust fitting to isolate vibrations and

allow for thermal expansion

Yes No N/A

12 Record air filter differential pressure:

Yes No N/A

6 Create / save air supply / exhaust layout

Yes No N/A

13 Record exhaust temperature stack:

Yes No N/A

7 Emission level verified within specifications

Yes No N/A

14 Record intake manifold air temperature:

Yes No N/A

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

Yes No N/A

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):

Yes No N/A

Notes:

8. Jacket Water & Space Heater

Notes:

9. Starter & Battery

Notes:

10. Cooling System

1 High water temperature shutdown

Yes No N/A

6 Coolant mixing ratios

Yes No N/A

2 Expansion tank highest level

Yes No N/A

7 Jacket water heater supply (Volts / Amps)

Yes No N/A

3 All guards & shrouds installed with proper

4 clearance
Discharge air unobstructed

Yes No N/A

8 (pressure test - record PSI)

Yes No N/A

Yes No N/A

Yes No N/A

5 Hot air recirculation prevented

Yes No N/A

9 Differential Temperature Radiator (ref. to A&I

Guide)

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

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:

12. Gen Syst - Electrical

Notes:

13. Gen Syst - Control Panel

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

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:

Yes No N/A

3 Verify against generator Volts / Amps

Yes No N/A

Notes:

16. Gen Syst - Voltage Regulators

LOAD

Record Values in boxes provided

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 CDVR/ECM replacement file saved

Notes:

Yes No N/A

17. Automatic Transfer Switch

1 Verify voltage/amperage

Notes:

Yes No N/A

2 Verify phase rotation

Yes No N/A

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

Component Manufacturer

Type

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

Remarks

Calibration Date

Date for evaluation of measuring

records (e.g. amplification, rate of
feed)