C7 - C32

MARINE PROPULSION

START-UP AND
COMMISSIONING
CHECKLIST
Table of Contents

Cover Sheet ............................................................................................................. 3 - 6

Pre Start-up Check ................................................................................................. 7 - 15

Start-up .................................................................................................................... 16

Vibration Levels ...................................................................................................... 17

References .............................................................................................................. 18
 C7 - C32 Marine Propulsion Startup
& Commissioning Checklist - Cover
Sheet

General
Selling Dealer: Vessel builder:
Vessel Name: OEM Model:
IMO Number: Flag State:
Home Port: Area of Operation:
Address:

Type of Sale: Retail Wholesale Repetitive One Time

Vessel Data
Hull Type: Displacement Semi-Displacement Planing
Length: Waterline length: Beam:
Design Draft: Actual Draft: Displacement:
Expected Hull Speed: Hull exponent:
(Free Running, Knots)

Vessel Type
Pleasure Craft: Cruiser Sportfish Yacht Sailboat Other
Tow Boat: River Intercostal Ocean Lower Mississippi Other
Fishing: Trawler / Dragger Long Liner Gillnetter Trap Fishing
Cargo: Bulk Container General
Other:

Application Information
Maximum expected altitude operation: Maximum / Minimum expected ambient air temp:
Engine installation angle & front/rear down?: Maximum expected Sea Water Temp:
Maximum expected tilt angle in operation: Expected average operation hrs. per year:
Anticipated Engine load factor: Anticipated percent of idle operation:

Propulsion System
Propulsion Engine:
Model: Rating: bhp bkW
Rated speed: Performance Rating: Test Spec:
Eng. Feature code: Performance Spec No.:
Engine S/N:
Major Attachments:
Position in Vessel: Port Center Starboard Other (Eng. No)
Torsional Vibration Yes Analyst: Report No:
Analysis performed: No

Marine Transmission
Manufacturer: Model: Serial No.:
Ratio: Fwd: Reverse:
Gear Oil Cooler
Specifications:

Coupling
Manufacturer: Model: Size:
Type: Serial No.:

Propeller
Propeller Type: Fixed Pitch Controllable Pitch Surface Drive Jet Drive
Manufacturer: Model: Material:
No. of Blades: Diameter: Pitch:

Cooling System
Type: ATAA Keel SWAC SCAC Central
Type of Cooler: Material: Area:
Type Fan Drive:
Type of Coolant: ELC Conventional Glycol SCA/Water Other
Brand: % Concentration:
Sea Water Strainers: Brand: Mesh Size:

Fuel System
Fuel Type: Brand: Sulfur Content (PPM):
Primary Fuel Filters: Brand: Mesh Size:
Other: Water Separator Duplex Filters
Biodiel (%)
Tank Height above engine inlet ( - if below): m Lift Pump (if below):
Fuel supply line inside diameter: mm length: m
Fuel return line inside diameter: mm length: m

Lubrication System
System options: Duplex Filters Centrifugal Pre-Lubrication Auxiliary Oil Sump
Type of Oil Sump: deep shallow Capacity: [ ltr / US Gal]
Oil specification: Oil filled to sump: [ ltr / US Gal]

Starting Systems
System options: Electric Pneumatic Hydraulic
Starter Manufacturer: Model:
Alternator Manuf.: Model: V A
Battery Manuf.: Model / Capacity: CCA (0°C): A
Number of Batteries: Starting Cable Size: Total length supply and return: m
Starting Aids: Glow Plugs
 Ether Aid
JW Heater Power: W Voltage: V
Inlet Air Heater Manufacturer Type/Model:
Lube Oil Heater
Exhaust System
Type: Dry Water Cooled (Wet) Lift Muffler (if wet)
Mufflers: Aftertreatment:
Expected System
[ kPa / in H2O]
Backpressure
Additional Information

Aftertreatment System (If Equipped)

Type: SCR SCR + DPF
Air Assist: Yes No
Switchable: Yes No Details:
Muffler Location: Before CEM After CEM
Dosing Cabinet
CEM Serial Number:
Serial Number:
Dosing Cabinet Part
CEM Part Number:
Number:
Bulk DEF Tank
[ ltr / US Gal]
Capacity:

PTO (If Installed)

PTO: Manufacturer: Model:
Rated Power: Serial No.: Location:

Throttle System
Type: Cat MSCS Cat Three60 Other
Manufacturer: Model: Signal:
Sync mode Slow vessel mode Trolling mode

Vessel instrumentation
Number of Stations: Type:
Location(s):

Mounting information
Type: Flexible Mounts Steel Shims Poured Shims Hard Mounted Collision blocks
Supplier of Flexible Mounts (if Equipped): Model:
Brand / Type of Epoxy Resign:
Tilt angle: Front up Front down Angle (Degrees):
to Left to Right Angle (Degrees):

Generator Set Specifications

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:
Delegated final assembly
Engine Derate:
contract #:

Engine System Controls

Diesel Control Unit Type: DCU Serial #:
Software Version: No of Remote Panels
Type of Remote Panel(s)

Environmental Conditions
Ambient Temperature: Elevation:
Engine Room Temp: Relative Humidity:
Atmospheric Conditions:

Storage and Insulation (Genset)

Generator Dried for 48 Hours Before Start- Visual Inspection Before Start-up -- Grease,
Yes No N/A Yes No N/A
up (See SEHS9124): Water, Debris, (Foreign Material):
Drying Method:

Installation and Load (Genset)

Neutral Grounding Systems: Yes No N/A Unit connected in parallel: Yes No N/A
Enclosure Weather Tight: Yes No N/A Load Diagram Created & Saved: Yes No N/A
Proper Ventilation: Yes No N/A Full Load Data Created & Saved: Yes No N/A
Description of load:
Motor SKVA:
Motor Total HP:
UPS Manufacturer:
UPS Model Number/Size:
UPS Serial Number:

Automatic Transfer Switch (Genset)

Manufacturer:
Model number:
Serial number:
Verify voltage/amperage Yes No N/A Check for loose or missing hardware: Yes No N/A
Verify phase rotation Yes No N/A All wires secure & check wire terminations: Yes No N/A
Set all timers & exerciser Yes No N/A Test for proper operation: Yes No N/A
Check for damage Yes No N/A

Customer Authorization to Service / Test

Customer Rep. Signature: Date:

Service Engineer Signature: Date:

Attachments
Documents: TVA Alignment Record Generator Insulation Ventilation Strategy
CAT ET Status Report CAMPAR Report Vibration Results Sound Test Results
Others:

Comments

Customer Acceptance

Customer Rep. Signature: Date:

Service Engineer Signature: Date:

 CATERPILLAR C7 - C32 MARINE PROPULSION 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.

Pre Start-up check

1. Safety and Serviceability
1 Personal protective equipment worn Yes No N/A 13 Fire extinguisher present & charged Yes No N/A
2 Hot pipes are wrapped Yes No N/A 14 Fire suppression unlocked & operational Yes No N/A
3 All hoses, piping & wiring is/are secure Yes No N/A 15 Pipe work & services are color coded/labeled Yes No N/A
If the engine was prepared for long term storage, be
4 Yes No N/A 16 Emergency stop functional Yes No N/A
sure that protections have been removed
5 Engine is free of damage Yes No N/A 17 Sight glasses are visible Yes No N/A
6 Floors are clean no hazards Yes No N/A 18 Gauges are functional (oil, fuel, air, other…) Yes No N/A
7 Floor openings are covered Yes No N/A 19 Air/Fuel/Oil Filters are accessible Yes No N/A
Emergency hatch identified, functional ,and
8 Yes No N/A 20 Adequate access to fluid fill locations Yes No N/A
unobsrtructed
9 Engine is mounted with all holding bolts secure Yes No N/A 21 Engine is properly grounded (refer to REHS4634) Yes No N/A
10 Warning decals & plates are installed Yes No N/A 22 Air intake free of airborne debris Yes No N/A
11 All guards and heat shields are in place Yes No N/A 23 Reviewed OMM, Parts Manual, Warranty, SOS Yes No N/A
Has operator / Chief Engineer been trained on engine
12 All safety shutdowns & warnings operational Yes No N/A 24 Yes No N/A
operation and maintenance
References:
Notes:

2. Fuel System and Fuel Storage

1 Tank fuel level is verified Yes No N/A 7 Fuel shutoff valves present and oeprational Yes No N/A
2 Fuel transfer pump ready to operate Yes No N/A 8 Fuel filter primed Yes No N/A
3 Properly vented fuel tanks Yes No N/A 9 Fuel pressure alarms verified Yes No N/A
4 Fuel line sizing verified Yes No N/A 10 Correct valve installed in the return Yes No N/A
5 Check for fuel leaks Yes No N/A 11 Take a fuel sample and send it to SOS Yes No N/A
References: LEGM4731, LEBW4976
Notes:
3. Lube System
1 Jacket oil heater operational Yes No N/A 7 Remove crankcase covers, plugs & tape Yes No N/A
2 Oil sample taken (SOS baseline sample) Yes No N/A 8 Check pre-lube installation Yes No N/A
3 Crankcase breather / filters installed and routed properly Yes No N/A 9 Check for leaks Yes No N/A
4 Document quantity of oil filled to sump Yes No N/A 10 Prelube pump working pressure meets specs Yes No N/A
5 Oil meets specifications Yes No N/A 11 check dip stick calibration. Yes No N/A
6 Oil Level gauge (dip stick) calibrated (per OMM) Yes No N/A 12 CAT DEO-ULS/ API CJ 4 oil sticker on all lube fill points Yes No N/A
References: LEBW4957
Notes:

4. Alarm Verification
1 Low water level Yes No N/A 9 Jacket Water Pressure Yes No N/A
2 High Jacket Water temperature Yes No N/A 10 MCS engine safety device (Diesel Control Unit) Yes No N/A
3 Low Jacket Water temperature Yes No N/A 11 Overspeed Yes No N/A
4 Low oil pressure Yes No N/A 12 Crank Terminate Yes No N/A
5 Low oil level Yes No N/A 13 High Exhaust temperature Yes No N/A
6 Low Fuel Pressure Yes No N/A 14 Neutral safety switch functional Yes No N/A
7 High Fuel Pressure Yes No N/A 15 Starter interlock functional Yes No N/A
Additional MCS alarm and protections demostrated and
8 E-Stop function Yes No N/A 16 Yes No N/A
verified by society surveyor
References:
Notes:

5. Governor Settings
Copy saved of the ECM replacement file or other record
1 Yes No N/A
governor settings saved
References:
Notes:
6. Intake System/Exhaust System
1 Check for damage Yes No N/A 8 Exhaust pipe properly supported and isolated Yes No N/A
2 Remove air filter bags / covers Yes No N/A 9 Exhaust bellows installed according to manf. Spec. Yes No N/A
3 Check exhaust water drain pipe & valves Yes No N/A 10 Emissions control unit installed & operational Yes No N/A
4 Air intake condensate drain provided Yes No N/A 11 Check for duct isolation Yes No N/A
5 Air filter housing seal present & serviceable Yes No N/A 12 Exhaust Temperature Port installed and accessable Yes No N/A
6 Check for missing or loose hardware Yes No N/A 13 Exhaust Backpressure Port installed and accessable Yes No N/A
7 Pre-lube turbo charger Yes No N/A
References: LEBW4969, LEBW4970
Notes:

7. Aftertreatment System
1 Dosing cabinet - Confirm dry air supply Yes No N/A 9 Check DEF concentration Yes No N/A
2 Dosing cabinet - confirm DEF supply to tank Yes No N/A 10 DEF lines properly routed Yes No N/A
3 Dosing cabinet - properly vented Yes No N/A 11 DEF pressure regulator/relief valve present if required Yes No N/A
4 Dosign cabinet - check for leaks Yes No N/A 12 Verify DEF pump operation Yes No N/A
5 Dosign cabinet - no ground fault interruption on 110 VAC Yes No N/A 13 Verify CEM serial number is compatible with engine Yes No N/A
6 Dosign cabinet - installed below injector lance Yes No N/A 14 Verify no insulation on NOx sensors Yes No N/A
7 Verify bulk DEF tank level Yes No N/A 15 Dosing test run to confirm proper operation Yes No N/A
Verify bulk DEF tank low level switch installed and
8 Yes No N/A 16 Delegated final assembly list completed and submitted Yes No N/A
functional
References: LEBM0023, LEBM0047
Notes:

8. Engine Room Ventilation

1 Check engine room ventilation Yes No N/A 6 Engine room exhaust fans installed and functional Yes No N/A
2 Combustion air ducted from outisde Yes No N/A 6a Engine room exhaust fan Diameter (mm) mm
Venitlation Airflow Type per LEBW4971
3 Type 1,2,3,4 6b Engine room exhaust fan Flow Rate per unit (CFM) CFM
(If other explain in Notes)
4 Engine room intake fans installed and functional Yes No N/A 6c Number of exhaust fan units in engine room Units
4a Engine room intake fan Diameter (mm) mm 7 Exhaust fans adequately sized per LEBW4971 Yes No N/A
4b Engine room intake fan Flow Rate per unit (CFM) CFM 8 Diagram of engine room venilation attached Yes No N/A
4c Number of intake fan units in engine room Units 9 Pictures of engine room ventilation attached Yes No N/A
If engine room provides combustion air, is the system
5 Yes No N/A
sized to provide required air flow per LEBW4969
References: Engine Room Design Considerations Guide, LEBW4971, LEBW4969
Notes:

9. Jacket Water & Space Heater

 1 Jacket water heater wiring and voltage correct Yes No N/A 3 110-240 V AC preheater grounding provided Yes No N/A
2 Verify JWH valve position is open during usage Yes No N/A
References:
Notes:
10. Starter & Battery
1 Inspect starter wiring Yes No N/A 9 Note starter cable length and size 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 Battery charging alternator operational check Yes No N/A 12 Charging alternator guards in place & secure Yes No N/A
5 Batteries connected properly Yes No N/A 13 Charging alternator belts inspected and adjusted Yes No N/A
6 Batteries isolated from floor Yes No N/A 14 water drained from Starting air line Yes No N/A
7 Batteries charged (deep cycle) before use Yes No N/A 15 Verify no stray voltage on block (record results in notes) Yes No N/A
8 Battery cables & racks properly installed Yes No N/A 16 Verify no stray voltage to hull (record results in notes) Yes No N/A
References: LEBM0001, LEBW4980
Notes:

11. Cooling System (Jacket Water and SCAC Systems)

1 Check for leaks Yes No N/A 9 Aux expansion tanks have sufficient expansion volume Yes No N/A
Verify aux expansion tank(s) shunt line is routed to
2 Check coolant level Yes No N/A 10 Yes No N/A
pump inlet.
Verify engine circuits are properly vented and the vent
3 System pressurized Yes No N/A 11 Yes No N/A
lines route to top of aux expansion tanks

4 Record pressure cap part no. Yes No N/A 12 Verify engine is filled and vented properly Yes No N/A
5 Isolation valves & drain valves installed Yes No N/A 13 Customer external cooling piping properly sized Yes No N/A
Confirm type of coolant and record chemistry makeup Customer external cooling circuits have strainers
6 Yes No N/A 14 Yes No N/A
including glycol % in Notes installed for commissioning
Customer piping and external coolers have been
7 High water temperature shutdown (see 4.15) Yes No N/A 15 Yes No N/A
properly strained of debris from vessel construction*
Customer connections to external cooling circuits are
8 Verify aux expansion tank(s) provide positive head * Yes No N/A 16 Yes No N/A
properly isolated form engine
References: Ref. EDS 50.5 9-87 Cooling System Field Test / SEBD0518-10 Know Your Cooling System / *LEGM4727
Notes:

12. Cooling System (Sea Water and SWAC Systems)

1 Check for leaks Yes No N/A 5 Record suction pipe diameter mm
2 Sea water strainers installed Yes No N/A 6 If zinc potected, verify zincs installed Yes No N/A
If electrically bonded, verify all components properly
3 Sea water strainer mesh size mm 7 Yes No N/A
bonded
4 Sea Valve (flanged gate or globe type) installed Yes No N/A
References: Ref. EDS 50.5 9-87 Cooling System Field Test / SEBD0518-10 Know Your Cooling System / *LEGM4727
Notes:
13. Mechanical
1 Package properly mounted Yes No N/A 4 Air shut-offs operational
2 Hoses routed properly (no kinks, sharp bends…) Yes No N/A 5 Motorized dampers are operational
3 Record vibration isolators serial numbers Yes No N/A
References:
Notes:

14. Main Engine - Control Panel

1 Secure all wires Yes No N/A 6 Verify remote panel control functionality Yes No N/A
2 Check all wire terminations for tightness Yes No N/A 5 Remote emergency stop(s) wired / functional Yes No N/A
3 Energize controls Yes No N/A 6 Verify settings (correct as needed) Yes No N/A
4 Verify control panel(s) start/stop functionality Yes No N/A 7 Check software & upload latest version
5 Verify local panel control functionality Yes No N/A
References:
Notes:

15. Main Engine - Throttle System

1 Secure all wires Yes No N/A 5 Verify Throttle Sync Yes No N/A
2 Check all wire terminations for tightness Yes No N/A 6 Verify settings (correct as needed) Yes No N/A
3 Energize controls Yes No N/A 7 Check software & upload latest version Yes No N/A
4 Check Ahead / Astern / Neutral functionalilty Yes No N/A
References:
Notes:

16. Coupling
1 Veryfy coupling type and serial number Yes No N/A 3 Alignment record attached Yes No N/A
2 Alignment requirements met Yes No N/A
References:
Notes:
17. Engine Mounting System
1 Verify flexible mount type and serial number Yes No N/A 2 Flexible mount central buffer clearance checked Yes No N/A
References:
Notes:

18. Coupling / Drive Train - Alignment

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

Face Indicator Readings

Initial / Final (mm)

Location A: /
Location B: /
Location C: /
Location D: /

Bore Indicator Readings

Initial / Final (mm)

Location A: /
Location B: /
Location C: /
Location D: /

Laser Alignment Results

Initial / Final
Horizontal Gap/Angle: /
Horizontal Offset: /
Vertical Gap/Angle: /
Vertical Offset: /
References:
Notes:
 Start-up
1. Safety and Serviceability
1 Reviewed start-up procedure and Safety Information Yes No N/A 6 Adequate access to oil spill prevention equipment Yes No N/A
2 Personal protection equipment worn Yes No N/A 7 Start Engine Yes No N/A
3 Floors are clean / no hazards Yes No N/A 8 Remote start/stop checked & operational Yes No N/A
4 Floor openings are covered Yes No N/A 9 Emergency stop functional Yes No N/A
5 Gauges are functional (oil, fuel, air, other…) Yes No N/A
Notes:

2. Systems
1 Check for correct oil pressure Yes No N/A 6 Emissions control unit operational Yes No N/A
2 Check for fuel or oil leaks Yes No N/A 7 Jacket water heater off when engine running Yes No N/A
3 Oil level is correct Yes No N/A 8 Prelube pump off when engine running Yes No N/A
4 Check intake and exhaust systems for leaks Yes No N/A 9 All temperature and pressure gauges reading Yes No N/A
5 Expansion tank(s) appropriate level Yes No N/A 10 take oil sample after 1st hr of running Yes No N/A
Notes:

3. Alarm Verification
1 Low oil level Yes No N/A 4 Remote E-Stops Yes No N/A
Additional MCS alarm and protections demostrated and
2 Over speed Yes No N/A 5 Yes No N/A
verified by society surveyor
3 E-Stop Yes No N/A 6 DEF fluid Level Yes No N/A
Notes:
4. Sea Trial
1 All fluid levels checked Yes No N/A 6 Install fuel flow meters Yes No N/A
2 Get vessel's load condition. Use nautical info form Yes No N/A 7 Engine at operating temperature Yes No N/A
3 Ask captain to log vessel speed every rpm step Yes No N/A 8 Sea trial conducted per Sea Trial Guide (LEBM0025) Yes No N/A
4 Measure API gravity and fuel Temp. Yes No N/A 9 Sea trial data loaded into CAMPAR and results attached Yes No N/A
5 Measure glycol protection Temp. Yes No N/A 10 safe ECM download Yes No N/A
References: LEBM0025
Notes:

Customer Acceptance

Customer Rep. Signature: Date:

Service Engineer Signature: Date:

 C7 - C32 Marine Propulsion Startup &
Commissioning Checklist Cover Sheet

1. Vibration Levels (optional)

Vibration levels - use for all in-line 6 (e.g. C9, C15, C18, 3406, 3456C…) Built after 1/1/04.
Reference LEBW4972 Vibration
Engine speed:
1/2 Order µm 1st Order µm Overall µm Overall mm/
Location Displacement mil Displacement mil Displacement mil Velocity sec Comments
MP 1
MP 2
MP 3
MP 4
MP 5
MP 6
MP 7
MP 8
MP 9
MP 10
MP 11

2. Particulars of Vibration Measurement Equipment

Manufactuter: Type:
Sensor:
Measuring Indicator Set:

Note: Terms are according to Caterpillar Vibration A&I guide LEBW4972

Mechanical Connection
Calibration Date
 System media number Type Title / description
Ventilation LEBW4970 A&I Guide EXHAUST SYSTEMS
Exhaust LEBW4970 A&I Guide EXHAUST SYSTEMS
LEBW4957 A&I Guide LUBRICATION SYSTEMS
SEBD0640 Special Instruction Oil and Your Engine
Cat Commercial Diesel Engine Fluids
SEBU6251
Special Publication Recommendations
SEBU6250 Special Publication Caterpillar Machine Fluids Recommendations
Optimizing Oil Change Intervals All Caterpillar Diesel
PEDP7035
Lubrication Special Publication Engines except on High Way
Caterpillar On-Highway Diesel Engine Fluids
SEBU6385
Special Publication Recommendations
Cat Gas Engine Lubricant, Fuel and Coolant
SEBU6400
Special Publication Recommendations
Cat 3600 Series and C280 Series Diesel Engine
SEBU7003
Special Publication Fluids Recommendations
LEGM4731 A&I Guide FUEL SYSTEMS, MARINE
LEBW4976 A&I Guide DIESEL FUELS & DIESEL FUEL SYSTEMS
Fuel
Cat Commercial Diesel Engine Fluids
SEBU6251
Special Publication Recommendations
LEBW4978 A&I Guide COOLING SYSTEMS
LEGM4727 A&I Guide COOLING SYSTEMS, MARINE
EDS 50.5 9-87 Engine Data Sheet Cooling System Field Test
Cooling Cat Commercial Diesel Engine Fluids
SEBU6251
Special Publication Recommendations
SEBD0518 Special Instruction Know Your Cooling System

Starting Systems LEBW4980 A&I Guide Starting Systems

Vibration LEBW4972 A&I Guide Vibration
Alignment LEBW4975 A&I Guide Alignment
Mounting LEBW4974 A&I Guide Mounting
Electronics LEBM0001 A&I Guide Marine Engine Electronics
Aftertreatment LEBM0023 A&I Guide CAT Clean Emissions Module
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow“ and the “Power Edge“ trade dress,
as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without ©2017 Caterpillar
permission. U.S. Sourced. All rights reserved.
Materials and specifications are subject to change without notice.
LEBM0038-01 The International System of Units (SI) is used in this publication.