ELECTRIC POWER

START-UP CHECKLIST

The following is a recommended start-up checklist intended for use during generator set
commissioning process. This general checklist is intended to help facilitate a standardized self-
assessment approach to commissioning. Theses checks are a representative sample, but not all-
inclusive of typical checks to be performed during generator set commissioning. The appropriate
Application and Installation guides, as we as the applicable Operation and Maintenance Manuals
(OMM’s) should be the prevailing reference during the generator set commissioning process. See
LEBW4950 (Engine Application & Installation Guide Table of Contents) for a list of resources.

Although Caterpillar Inc. warrants the performance of the generator set pursuant to the applicable
warranty statements, the responsibility for the proper generator set application and installation in
accordance with Caterpillar’s required and recommended installation procedures rests with the
installing dealer(s). Caterpillar Inc. and Foley Power Solutions assumes no responsibility for
deficiencies in the installation. Proper installation is critical for quality generator set performance and
compliance. Caterpillar Inc. or Foley Power Solutions does not guarantee or approve the validity or
correctness of any installation, and Caterpillar’s sole obligation with respect to any product is as set
forth in the applicable Caterpillar warranty statement.

Once completed, this checklist should be maintained exclusively by the installing dealer(s) as a history
of the product’s commissioning process. For example, future reference of this checklist could prove
beneficial in resolving any Caterpillar product support issues, or any other issues associated with the
generator set commissioning process.

DEALERSHIP AND CUSTOMER ACKNOWLEDGEMENTS

INSPECTING DEALERSHIP ACKNOWLEDGEMENT: It is hereby certified that the start-up checklist as

specified in this form has been completed and the generator set is commissioned. As an authorized Caterpillar
dealer, I understand my responsibilities to properly commission the Caterpillar generator set in accordance
with Caterpillar’s Application and Installation guides.

also acknowledge the following:

1). All operating controls function per manufacturer’s specifications.
2). All safety devices function per manufacturer’s specifications.
3). Comments made on this form best describe the condition of the equipment at commissioning.

Name of lead technician in charge of commissioning: _____________________________________________

Dealership Service Manager Name (clearly printed/typed): ________________________________________

Dealership Service Manager Signature: _______________________________ Date: _________________

CUSTOMER ACKNOWLEDGEMENT: I acknowledge that the dealership has explained this start up check list

to me. Customer Name (clearly printed/typed): ________________________________________________

Customer Signature: ______________________________________________ Date: _________________

FPS Startup Form v1.0 Page 1 of 7

 ELECTRIC POWER
START-UP CHECKLIST

Reset COMMISSIONING DEALER

Commissioning
Caterpillar Dealer: _______________________________ Dealer Code: ______ Date: _______________

CUSTOMER INFORMATION

Customer Name: _______________________________ Contact Name ____________________________

Address: ______________________________________________ City: ___________________________

State / Province: __________ Postal Code: _____________ Country: _____________________________

Phone: _________________________________ Email: _________________________________________

Reset GENERATOR SET INFORMATION

Package Serial Number: ________________________ Type of Installation: __________________ Fuel Type: ________________
Generator Serial Number: ________________________________ Engine Model Group: __________________________________
Engine Serial Number: _____________________________ Generator Arrangement Number: ______________________________

Comments

Reset SAFETY AND SERVICEABILITY

 YES  NO  N/A Genset is free of damage  YES  NO  N/A Level indicators are accessible
 YES  NO  N/A Genset is level with all holding bolts secure  YES  NO  N/A Spillage containment acceptable
 YES  NO  N/A Hot pipes are wrapped  YES  NO  N/A Sight glasses are visible
 YES  NO  N/A All hoses, piping & wiring is secure  YES  NO  N/A Key components are labeled
 YES  NO  N/A Remote start/stop checked & operational  YES  NO  N/A Gauges are functional (oil, fuel, air, other...)
 YES  NO  N/A Emergency stop functional  YES  NO  N/A Proper grounding (refer to REHS4634)
 YES  NO  N/A Adequate access to fluid fill areas  YES  NO  N/A Engine room noise level policy satisfied
 YES  NO  N/A Air / Oil / Fuel filters are accessible  YES  NO  N/A Air intake free of airborne debris
Comments

Reset FUEL SYSTEM AND FUEL STORAGE

 YES  NO  N/A Check fuel lines for leaks  YES  NO  N/A Proper operation of fuel tank alarms
 YES  NO  N/A Fuel transfer pump properly installed  YES  NO  N/A Properly connected fuel return/overflow
 YES  NO  N/A Fuel filters tightened lines Fuel filter primed
 YES  NO  N/A Day tank properly installed in relation to  YES  NO  N/A Fuel filter not damaged
the engine.
 YES  NO  N/A Properly vented fuel tanks
 YES  NO  N/A Citical fuel level shutdown  YES  NO  N/A Fuel tank plugs properly installed
 YES  NO  N/A Tank fuel level is verified  YES  NO  N/A No unusual fuel tank noises / vibrations
Comments

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 ELECTRIC POWER
START-UP CHECKLIST
Reset MECHANICAL
 YES  NO  N/A Inspect belts, hoses & connections  YES  NO  N/A Overspeed shut-down is correct
 YES  NO  N/A Inspect supports & vibration isolators  YES  NO  N/A Over-crank shut-down is correct
 YES  NO  N/A Inspect fan drive  YES  NO  N/A Motorized dampers are operational
 YES  NO  N/A Air shut-off is operational  YES  NO  N/A Verify attachments
Comments

Reset LUBRICATION SYSTEM

Oil Type: ____________________________________________

YES NO N/A Oil level is correct YES NO N/A Jacket oil heater operational
YES NO N/A Check for leaks YES NO N/A Verify proper lubrication of pre-lube pumps
YES NO N/A Check for oil contamination YES NO N/A Install crankcase breather hose if necessary
YES NO N/A Check seals for leaks YES NO N/A Pipes routed through front end of base
YES NO N/A Oil pressures within specifications YES NO N/A Remove crankcase covers, plugs & tape
YES NO N/A Check for unusual noises & vibrations

Comments

Reset COMBUSTION AIR

YES NO N/A Check for damage YES NO N/A Check exhaust water drain
YES NO N/A Check for leaks YES NO N/A Check all exhaust flanges, joints & welds
YES NO N/A Check intake air system YES NO N/A Check for manifold damage
YES NO N/A Remove air filter bags / covers YES NO N/A Check for missing or loose hardware
YES NO N/A Air filter gasket serviceable YES NO N/A Exhaust installation allows for expansion
YES NO N/A Air filter housing free of damage YES NO N/A Exhaust pipe properly supported
YES NO N/A Check exhaust cowl & rain cap

Comments

Reset JACKET WATER HEATER AND SPACE HEATER

YES NO N/A Jacket water heater wired correctly YES NO N/A Verify JWH valve position is open during usage
YES NO N/A Correct jacket water heater supply voltage YES NO N/A Space heater functioning properly
YES NO N/A Jacket water heater power on

Adjust thermostat record setting: ______________ Space heater voltage: ________________

Record block temperature: ___________________

Comments

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 ELECTRIC POWER
START-UP CHECKLIST

Reset STARTER AND BATTERY

YES NO N/A Inspect starter wiring YES NO N/A Condensate drain provided
YES NO N/A Starter operational check YES NO N/A Charging alternator guards in place & secure
YES NO N/A Cycle crank timer YES NO N/A Charging alternator belts properly adjusted
YES NO N/A Check oil lubrication YES NO N/A Batteries connected properly
YES NO N/A Air / hydraulic compressor operational YES NO N/A Batteries isolated from floor
YES NO N/A Isolation valves correctly positioned YES NO N/A Battery cables & racks properly installed

Comments Charge Rate (need data value): ___________________ Amps

Reset COOLING SYSTEM

YES NO N/A Check for leaks (pressure test – record PSI) YES NO N/A All guards & shrouds in place
YES NO N/A Check coolant level YES NO N/A Correct alignment of fan belts / pulleys
YES NO N/A Check for damage & unusual noise YES NO N/A Discharge air unobstructed
YES NO N/A Lubricate pully/drive bearings if applicable YES NO N/A Auxiliary supply voltage to fans correct
YES NO N/A Check antifreeze (refer to A&I guide) YES NO N/A Proper clearance between fans, shrouds
YES NO N/A Isolation valves & drain valves installed & guards
YES NO N/A Drain valves routed correctly YES NO N/A Check fan / drive / pulley belts tension
YES NO N/A Piping complete & tight

Coolant mixing ratios: ______________ Jacket water heater supply voltage: ________________ AC (volts/amps)
Comments

Reset GENERATOR SYSTEM (Electrical)

YES NO N/A Unit is properly grounded (REHS4632) YES NO N/A Connctions completed to transfer switch
YES NO N/A Check AC & DC Electrical connections YES NO N/A All covers are in position and secure.
YES NO N/A Check for loose wiring & secure

Comments

Reset GENERATOR SYSTEM (Mechanical)

YES NO N/A Check for loose or missing hardware YES NO N/A Check for tight connections
YES NO N/A Clean all debris from the area
YES NO N/A Confirm bearing grease fitting is accessible <= (greasing not required at startup)

Comments

Reset GENERATOR SYSTEM (Circuit Breaker)

YES NO N/A Test any alarms / shunt trips YES NO N/A Verify against generator Volts / Amps
YES NO N/A Check for tight connections
Record circuit breaker settings (sizes): CB#1 __________ CB#2 __________ CB#3 __________ CB#4 __________ amps
Comments

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 ELECTRIC POWER
START-UP CHECKLIST
Reset GENERATOR SYSTEM (Control Panel – EMCP)
YES NO N/A Verify settings (correct as needed) YES NO N/A Verify all alarms
YES NO N/A Secure all wires YES NO N/A Check generator remote controls
YES NO N/A Check all wire terminations for tightness YES NO N/A Check condition / operation of meters
YES NO N/A Energize set & system controls YES NO N/A Remote emergency stop wired / functional
YES NO N/A Verify operation of annunciator YES NO N/A Verify engine / generator shutdown
YES NO N/A Check software & upload latest version YES NO N/A Verify interconnect wiring
YES NO N/A Check auto / manual stop operation YES NO N/A Check generator system controls
YES NO N/A Check generator local controls YES NO N/A Select set parameters on system (ECM download)

Comments

Reset GENERATOR SYSTEM (Voltage Regulator)

YES NO N/A Adjust Generator Voltage YES NO N/A CDVR/ECM replacement file saved
YES NO N/A Adjust Generator Frequency YES NO N/A All settings verified
YES NO N/A Verify Phase Rotation YES NO N/A Map CDVR as required for site application.
YES NO N/A Confirm High-Leg Connection on 240V IE: Heavy Motor Starting.
3-Phase. YES NO N/A Install latest software version
Comments Record Power Factor: __________

Reset AUTOMATIC TRANSFER SWITCH(s)

YES NO N/A All wires secure & check wire terminations YES NO N/A Verify voltage / amperage
YES NO N/A Test for proper operation YES NO N/A Verify phase rotation
YES NO N/A Set all timers & exerciser YES NO N/A Check for damage
YES NO N/A Check for loose or missing hardware
Set and Record Exercise Day/Time: ______________________
ATS1 Voltage: _____ Amps: _____ # Poles: _____ ATS4 Voltage: _____ Amps: _____ # Poles: _____
MFG : _______________________________ MFG : _______________________________
Model #: _______________________________ Model #: _______________________________
Serial # : _______________________________ Serial # : _______________________________
ATS2 Voltage: _____ Amps: _____ # Poles: _____ ATS5 Voltage: _____ Amps: _____ # Poles: _____
MFG : _______________________________ MFG : _______________________________
Model #: _______________________________ Model #: _______________________________
Serial # : _______________________________ Serial # : _______________________________
ATS3 Voltage: _____ Amps: _____ # Poles: _____ ATS6 Voltage: _____ Amps: _____ # Poles: _____

MFG : _______________________________ MFG : _______________________________

Model #: _______________________________ Model #: _______________________________
Serial # : _______________________________ Serial # : _______________________________
Comments

Reset ANY ADDITIONAL COMMENTS OR NOTE

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