3500 DIESEL EPG

COMMISSIONING - FIELD
DATA RECODING SHEETS

ECM Parameter Settings Record:

For EUI engines list all the programmed parameters. Keep a record of any changes by
recoding the settings before and after a change.
Engine Overspeed

Engine Serial Number

ECM Serial Number

Warning Trip Point

Rated Fuel Position

Warning Delay Time

Low Idle Speed

Shutdown Trip Point

Acceleration Delay Time

Shutdown Delay Time

Acceleration Ramp Rate

Air Inlet Restriction

Cooldown Time
Cooldown Speed

Warning Trip Point

Prelube Time

Warning Delay Time

Crank Duration

Derate Trip Point

Total Number of Crank Cycles

Derate Delay Time

Air Shutoff

Altitude

Fuel Control
Direct Fuel Control Mode

Derate Trip Point

Record the following information from the engine

information plate.
Engine serial number
Record the following information from the engine
monitoring system.
ECM Voltage

High Exhaust Temperature

Warning Trip Point
Warning Delay Time
Derate Trip Point

Warning Trip Point

Delay Time

Warning Delay Time

Engine Oil Filter Differential Pressure

Engine Oil Pressure
Warning Trip Point
Warning Trip Point

Warning Delay Time

Warning Delay Time

Shutdown Trip Point

Fuel Filter Differential Pressure

Shutdown Delay Time

Warning Trip Point

Warning Delay Time

High Coolant Temperature

Crankcase Pressure

Warning Trip Point

Warning Delay Time

Warning Trip Point

Derate Trip Point

Warning Delay Time

Derate Delay Time

Shutdown Trip Point

Shutdown Trip Point

Shutdown Delay Time

Shutdown Delay Time

Aftercooler Temperature
Low Coolant Temperature

Warning Trip Point

Warning Trip Point

Warning Delay Time

Warning Delay Time

Derate Trip Point

Derate Delay Time
Shutdown Trip Point
Shutdown Delay Time

-2-

Customer Data:
Name

Start up date

Contact

Time

Telephone
Site
Type of Installation
Application:

PP

Continuous

Peak Shave

Engine Data:

Standby

Industrial

Other

Generator Data:

Engine Model

Serial Number

Serial Number

Arrangement

Arrangement

Rating

TMI Spec

Voltage

Rating

Marine

BHP

BkW

Amperage

Environment:
Ambient Temperature

Room Temperature

Elevationr
Atmospheric Condition

Relative Humidity
Salty

Dusty

Wet

Clean

Other:

Safety:
Heat Shields on Engine

OK - Not OK - N/A

All Guards in place

OK - Not OK - N/A

Emergency Stop Operates

OK - Not OK - N/A

Floor Openings Covered

OK - Not OK - N/A

Engine Room Noise Level

OK - Not OK - N/A

Floors Clean

OK - Not OK - N/A

Warning Decals in Place

OK - Not OK - N/A

Hot Pipes Wrapped

OK - Not OK - N/A

Fire Extinguisher

OK - Not OK - N/A

Wiring Secure

OK - Not OK - N/A

Fire Suppression System

OK - Not OK - N/A

Piping and Hoses Secure

OK - Not OK - N/A

Access to Fluid Fill Areas

OK - Not OK - N/A

OK - Not OK - N/

Serviceability:
Overhead Clearance

Gauges Accurate

Side Clearance

Oil

OK - Not OK - N/A

Air Filters Accessible

OK - Not OK - N/A

Water

OK - Not OK - N/A

Oil Filter Accessible

OK - Not OK - N/A

Fuel

OK - Not OK - N/A

Fuel Filter Accessible

OK - Not OK - N/A

Air

OK - Not OK - N/A

Site Glass Visible

OK - Not OK - N/A

Exhaust

OK - Not OK - N/A

Level Indicators

OK - Not OK - N/A

-3-

Customer Orientation
Safety practices (Refer to OMM)

OK - Not OK - N/A

Manuals

OK - Not OK - N/A

Operation and Maintenance Manual delivered and explained

OK - Not OK - N/A

Reviewed start up procedure

OK - Not OK - N/A

Pre-delivery Report

OK - Not OK - N/A

Service manual delivered and explained

OK - Not OK - N/A

Parts manual delivered and explained

OK - Not OK - N/A

Proper levels

OK - Not OK - N/A

Proper fluids

OK - Not OK - N/A

Delivery Service Completed

OK - Not OK - N/A

Warranty information explained

OK - Not OK - N/A

SOS service explained and offered

OK - Not OK - N/A

Maintenance contract advantages explained and offered.

OK - Not OK - N/A

Load Test Report Presented

OK - Not OK - N/A

As Built Drawings Delivered

OK - Not OK - N/A

Customer Acceptance Test

OK - Not OK - N/A

-4-

Engine Commissioning Checklist:

Governor:
Governor / Actuator type
Linkage free

OK - Not OK - N/A

Oil Level

OK - Not OK - N/A

Fuel System Information:

High Idle Setting:

Specification

Low Idle Setting

Specification

Fuel Type:

Fuel Treatment

OK - Not OK - N/A

Fuel API:

Fuel Line Isolated

OK - Not OK - N/A

Fuel Filter Pressure Differential:

Fuel Tanks Full & lines Open

OK - Not OK - N/A

Fuel Pressure:

Specification:

Check for Fuel Leaks

OK - Not OK - N/A

Anti Siphon Valves Fitted

OK - Not OK - N/A

Day Tank operation

OK - Not OK - N/A

(1)Day Tank Elevation

OK - Not OK - N/A

(2)Day tank Distance to Engine

OK - Not OK - N/A

(1) The full level of the day tank should be lower than the injector height of the engine
(2) The day tank should be no more than 15m away.

Cooling System:
+JW Inlet Temp:

+JW Outlet Temp

+SCAC Water Inlet Temp

+SCAC Water Outlet Temp

*Fill Test

OK - Not OK

Full Load Temperature

OK - Not OK - N/A

*Draw Down Test

OK - Not OK

Antifreeze

OK - Not OK - N/A

*Cavitation Test

OK - Not OK

Radiator Temp Differential

OK - Not OK - N/A

*Air Venting Test

OK - Not OK

Coolant Level Check

OK - Not OK - N/A

Check for Leaks

OK - Not OK - N/A

*Ambient Capability Value

+ At Rated Load
* Refer to EDS 50.5

Lubrication System:
Oil Filter pressure Differential

OK - Not OK - N/A

Oil Level Check

OK - Not OK - N/A

Oil Pressure Level

OK - Not OK - N/A

Check for Oil Leaks

OK - Not OK - N/A

Duct Isolation

OK - Not OK - N/A

Temperature AC

Check for Leaks

OK - Not OK - N/A

+Air Filter Pressure Diff

+Intake Manifold Pressure

+Total Inlet Restriction

+Intake Manifold Temperature

Combustion Air:
Temperature in

+ At Rated Load

-5-

Exhaust System-*
Exhaust Back Pressure

Exhaust Pipe Isolation

Exhaust Temperature Before Turbo

Check for Leaks

Exhaust Stack temperature

Port Temperatures
Right Bank

Left Bank

Cylinder 1:

Cylinder 2:

Cylinder 3:

Cylinder 4:

Cylinder 5:

Cylinder 6:

Cylinder 7:

Cylinder 8:

Cylinder 9:

Cylinder 10:

Cylinder 11:

Cylinder12:

Cylinder 13:

Cylinder 14:

Cylinder 15:

Cylinder 16:

Average Right Bank:

Average Left Bank:

Total Average:

Maximum difference from Average:

Hottest to coldest Differential:

All Figures

OK / NOT OK

* All to be done at Rated load

Mechanical:
Loose Bolts

OK - Not OK - N/A

Attachments

OK - Not OK - N/A

Inspect Belts

OK - Not OK - N/A

Alternator

OK - Not OK - N/A

Inspect fan

OK - Not OK - N/A

Air Shut-off

OK - Not OK - N/A

Hoses and Connections

OK - Not OK - N/A

Check for Leaks

OK - Not OK - N/A

Inspect Supports

OK - Not OK - N/A

Unusual Noises

OK - Not OK - N/A

Lubrication Points

OK - Not OK - N/A

Cleanliness

OK - Not OK - N/A

Vibration Isolator Adjustment

OK - Not OK - N/A

Vibration Isolator Type

-6-

Vibration Levels:
Order of Vibration Measured in mm
Overall m/s

st

nd

EFV(1)
EFH(2)
ERV(3)
ERH(4)
GFV(5)
GFH(6)
GRV(7)
GRH(8)
GRA(9)
ERR(10)
BASE(11)

Limits are as follows.

Peak to Peak Half Order - 0.13mm
Peak to Peak First Order - 0.13mm
Overall Displacement - 0.22 mm
Overall Velocity - 34.3 mm/s

Batteries
Charged

OK - Not OK - N/A

Trickle Charger

OK - Not OK - N/A

Electrolyte

OK - Not OK - N/A

Charge rate

OK - Not OK - N/A

Isolated from floor

OK - Not OK - N/A

Leads well secured

OK - Not OK - N/A

Wired Correctly

OK - Not OK - N/A

Power on

OK - Not OK - N/A

Inspect wirings

OK - Not OK - N/A

Jacket Water Heaters

Temperature Setting
Correct Orientation

OK - Not OK - N/A

Starter
Type

-7-

rd

Crankcase Ventilation
Type of Fumes Disposal

Ingestive Y / N

Filter

Y/N

Number of Breathers
Liquid Discharge Trap

Y/N

Location of Discharge

Leaks

OK - Not OK - N/A

*Crankcase pressure

Separate system per Engine

OK - Not OK - N/A

* Limits on Crankcase pressure:

For an injestive system the minimum crankcase pressure allowed is 25mm H2O Vacuum.
For a non-injestive system the maximum crankcase pressure allowed is 13mm H2O Positive.

Protection System Accuracy & Functional Tests.

High Water Temp

OK - Not OK - N/A

Low Water

OK - Not OK - N/A

Low Oil Pressure

OK - Not OK - N/A

Shutdown Devices

OK - Not OK - N/A

High Oil temperature

OK - Not OK - N/A

High Air Inlet Temperature

OK - Not OK - N/A

Over Speed

OK - Not OK - N/A

-8-

Generator Startup Checklist:

RATING INFORMATION
Engine Serial Number:
___________________________________

Arrangement Number: ___________________

Generator Serial Number:

_________________________________

Arrangement Number: ___________________

GENERATOR NAME PLATE INFORMATION

Voltage: ___________________

Package (prime, continuous, standby): _________________

Amperage: _________________

Kilowatts: ________________________________________

Storage Location:
Crankshaft Deflection:
Generator Alignment:
Main Stator Megohmmeter
Reading:

Before Storage:

Generator dried for 24 hours prior to startup?

SPACE HEATERS

After Storage:

(Y/N)

Yes

No

30 sec.
reading

60 sec.
reading

Drying method:
Comments

Space heaters operating properly?

Space heater operated 48 hrs.
before startup?
MEGOHMMETER TEST
(SEHS9124)
Beginning of
Storage

Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator

Start-up

Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator

-9-

30 sec.
corrected

60 sec.
corrected

Ambient
temp.

Comments

Regulator
No Load

Full Load

Voltage

F1 to F2

DC

20 to 22

AC

20 to 24

AC

22 to 24

AC

24 to 30 (SE only)

AC

26 to 28 (PM only)

AC

26 to 30 (PM only)

AC

28 to 30 (PM only)

AC

Generator
Excitation Name
Plate Information:

DC

F1 to F2

DC

20 to 22

AC

20 to 24

AC

22 to 24

AC

24 to 30 (SE only)

AC

26 to 28 (PM only)

AC

26 to 30 (PM only)

AC

28 to 30 (PM only)

AC

Amps

Comments

Compare with F1 to F2

ELECTRICAL

Yes

No

Comments

Unit properly grounded

Check diodes
Over current protection
Over voltage protection
Check for loose wiring
Adjust voltage
Adjust frequency
MECHANICAL

Data

Bearing temperature readings at full load

Front __________ Rear ___________

Stator temperature readings at full load

A0 _______ B0 _______ C0 _______

Air gap on main stator

Top __________ Bottom __________

Air gap on exciter stator

Top __________ Bottom __________

Air gap of PMG

Top __________ Bottom __________

Ambient air to generator at full load

Temperature ____________________

Supplier air opening to generator

Size of Opening _________________

- 10 -

Comments

SWITCH GEAR/PARALLEL OPERATION

Manufacturer:
Utility Grade:
PLC Manufacturer:
Software:
Busbar Current Rating:
Circuit Breaker Manufacturer:
Data Communication: SCADA
Communication

OK - Not OK - N/A

Setting 1

Setting 2

Circuit breaker type

Overload setting
Reverse power relay
VAR/PF Controller
Load share
INSTALLATION & LOAD INFORMATION
Neutral grounding system

UPS

Enclosure type

- Size

Motor:

Other loads:

- Total SKVA

- Lighting

- Total HP

- Computers
- Welding
- Non-linear
- Other

AC Functional Tests
AC Protection Function Test

OK - Not OK - N/A

Reverse Power Protection

OK - Not OK - N/A

Under Frequency Protection

OK - Not OK - N/A

Over Frequency Protection

OK - Not OK - N/A

Over Voltage Protection

OK - Not OK - N/A

Cable Installation
Cable Entry Location

Top / Bottom

Cable Size
Number of Cores

OK - Not OK - N/A

Cable Try

OK - Not OK - N/A

Cable Ladder

OK - Not OK - N/A

Cable Lay Out

OK - Not OK - N/A

FULL LOAD DATA

Voltage

Amps

KW

KVARS

P.F.

- 11 -

Setting 3

Comments

Statement of Completion:
The following section I to be completed and signed off by the authorized
mechanic, or mechanics, that have carried out the works to verify that the
numbers contained in this report are an accurate reflection of the readings
taken during the commissioning of the Generator Set / Engine.
The Caterpillar authorized selling dealer is to also sign off that all works have
been completed to their satisfaction and the customer to sign off as having
received a coy of this document for their records.
Installation Mechanic:
Name:
Title:
Signature:
Date:
Additional Mechanic:
Name:
Title:
Signature:
Date:
Selling Dealer:
Name:
Title:
Signature:
Date:
Customer:
Name:
Title:
Signature:
Date:

- 12 -