commisioning caterpillar genset after overhaul

[johngladstone]

Dears
I looking for help to determine the steps of commoioning required after overhaul of caterpillar genset 508 kw after overhaul any datasheet or pdf will be helpfull??
I appresiate for any help
Thanks in advance

 

[catserveng]

CAT doesn't have a specific instruction for startup after overhaul, there are some guidelines for the larger engines, but not for anything your size.

I can provide the following from a checklist I used when I worked for the dealer. This is simplified and contains info from multiple test sheets, application (standby, prime, cogeneration)had impact on actual work plan.

After engine assembly completed, prior to hooking up batteries or opening start air, after all engine fluids filled, bar engine over two complete revolutions by hand, assure turns freely.

Hook up batteries/open start air, crank engine over manually for several seconds, observe no abnormal noises and that oil pressure starts to build.

Open fuel supply and return valves, bleed fuel system as needed.

If electronic engine, power ECM, read and record parameters.

Assure air dams are open if equipped.

Check area for tools, trash, parts or any debris, make sure owner ready for engine start. Disable AVR by pulling PM fuses.

Start and run engine at idle, check for leaks or unusual noises, run engine at least 1 but no more than 5 minutes at idle, perform normal stop on engine, assure stop system works as required.

Pull valve covers as needed to verify oil up to rocker mechanisms. Reinstall valve covers.

Restart engine, run engine at idle until verified for proper operation, pressures and temperatures, ramp to rated speed. Check engine for leaks, unusual noises, vibration, any abnormal conditions. Stop engine with E-Stop, make sure fuel and air (if equipped with air dams) function as expected.

Restart engine and perform low oil pressure safety check. Repeat for all required safety checks. At minimum low oil pressure, high jacket water temperature, overspeed and E-Stop circuits will be verified on ALL engines, NO EXCEPTIONS.

With engine stopped, re-enable AVR. Start engine, observe proper voltage buildup and frequency.

Perform any additional customer required safety or function checks as needed, document.

Load Testing,

Start and run engine, warm up as needed. Load engine to 25% load, run at this load for 15 minutes, then record data on load test sheet.

Increase load to 50%, run at this load for 15 minutes, then record data on load test sheet.

Increase load to 75%, run at this load for 15 minutes, then record data on load test sheet.

Increase load to 100%, run at this load for minimum of 2 hours, take and record readings every 30 minutes. Assure temperatures and pressures stabilize in normal ranges. Observe stack outlet early and later in testing, stack should be clearing after 1 hour at full load.

After 1 hour at 100% take vibration readings (if required).

At completion of testing, take oil and coolant sample. Stop engine. Remove and inspect oil filter element (one element from multiple element filter assembly). Review ECM if electronic engine, save a Product Status Report.

Make sure all required data taken and documented, clean up area around engine.

Hope this helps, Mike L.

 

[johngladstone]

Dear catserveng:
Really I appresiate for your quick reply and answer I get some questions as follws:
1-what is the conditions must refuse to receive the genset after major overhaul from the vendors???
2-is the manufacture put some recommendatiin for lubricating oil if it decrease ????
3-what is the conditions that must refuse the genset after major or top overhaul from the vendors with scintific reasons ???
4-have you get any pdf document for the large engines???
5-is these same steps for top overhaul???
6-have you get any scope of works prepared to top overhaul or majour overhaul required from the vendors ????


Really I appresiate for your help catsengserv