CC/QA-ED/F013/ Rev 009 DATE –18.08.

2016
GENSET FINAL CHECK
SHEET
Prepared by : QA engineer Approved by : HOD QA

Genset Model No Genset Sr. No. Engine Model No. Engine Sr. No. Alternator No. STAMFORD Date
MECCALTE
CR. GREAVES
Inspector Name Supervisor Name
Kva/phase:- A. Visual aspect (R009) :-
OK / REMARKS IF OK/N REMARK IF NOT
SPECIFICATION/DESIRE CHECK POINT
SPECIFICATIONS / DESIRE / CHECK POINTS NOK NOK OK OK
A. Fuel tank Assembly / Make - H. Electrical system –Wiring harness fitment
Check Connection of Engine & canopy
1 Foam fitment. 1
wiring harness
Fitment of fuel tank into base frame (Location & Connection of ECU ,Cam sensor, Crank
2 2
resting bolt fit) sensor,IMV Pump
Feed pump (with O-ring) & Fuel Gauge assembly Connection of T-Map sensor, Oil
3 3
with gasket, Assembly of Fuel filling hose pressure sensor & switch
Connection of Rail pressure, injector
4 Lekage test identification 4
sensor
Vent pipe, fuel lock, feed pump bracket with fuel Connection of Coolant temp Switch &
5 5
tank, Leak proof gasket use Sensor
Check fitment of engine, alternator, radiator Connection of Fuel feed pump, Starter,
6 6
mounting member Fuel gauge
Earthing Connection with body to Panel
B. Engine Alternator sub assembly fitment on Base frame 7
& Alternator
Engine mounting support bracket assembly Connection of Roof lamp, power cable,
1 8
(Intake side & Exhaust side) control panel fitment

9
2 Foundation bolts tightening by 60 Nm torque Battery serial no -
(7)

AVM selection (grade) & bolts tighten by 60 Nm &

3 I. Battery connection / Make -
50 Nm
Engine and Alternator coupling – fasteners
4 1 Battery mounting assembly
tightening torque 50 Nm
Connection Starter motor, Earthing to
C. Coolant system fitment by using Hose & clips 2
main body
Cooling system Assembly (Radiator Outlet to
1 Engine inlet) & (Engine outlet to radiator Inlet) – 2 J. Canopy Make:- (Regular or Compact)
Cyl. Genset
Thermostat to radiator Pipe & Hoses assembly-3,4 Canopy top fitment,lifting hook,coolant
2 1
& 6 Cyl. & oil filling caps
Coolant Manifold To Radiator Pipe& hose Canopy : No damage, dent, color
3 2
assembly - 3,4 & 6 Cyl. scratch, Peel off, Shades
D. Air intake & exhaust sytems assembly 3 Foam : Adequacy, Pasting
Position CAC pipe (intake side) with gasket on No uneven Doors gap, Top panels,
1 4
intake manifold & Exhaust side CAC Assembly Louvers, Side panel
Fastener tighten with spring washer to
2 Gas mixer Pipe to radiator assembly 5
canopy, Rat mesh
3 Turbocharger to CAC pipe assembly 6 Oil drain bolt & piping available

4 Air Filter Assembly 7 Working condition of Fuel & Door locks

E. Radiator mounting assembly , fan guard assembly K. Sticker

1 Fan assembly & fan gap check visualy 1 Engine & genset name plate

2 Auxiliary tank connections (tank to radiator) 2 Sticker : Cooper logo, Genset KVA
Sticker : Emergency stop, helpline &
F. Exhaust System Assembly checks 3
instruction label
Fastener fitment to Elbow, Expansion bellow, L-
1 Bend pipe, Tail Pipe,Silencer & Mounting Bkt. & L. Packing (rev 03: 11.7.2015)
insulation – 2 cyl.
Check S pipe , Exhaust bellow , Exhaust pipe,
2 M As per SOP
silencer & tail pipe assembly – 3,4,& 6 Cyl.
G. Fuel supply & return pipe Assembly

1 Fuel System assembly

Check Connection : Pump to fuel filter, Filter to
2 IMV, Venturi to Feed pump, Fuel return to
venturi connection
 CC/QA-ED/F013/ Rev 009 DATE –18.08.2016
GENSET FINAL CHECK
SHEET
Prepared by : QA engineer Approved by : HOD QA

B. PERFORMANCE INSPECTION PARAMETERS

SR.N SPECIFICATIONS / DESIRE / CHECK OK /
ASPECT REMARKS IF NOK
o. POINTS NOK
01 Check engine oil level MAX / MIN dip stick -MAXIMUM LEVEL

02 Check coolant level Visual

03 White / black smoke no smoke allowed

04 If charging alternator use check the voltage output

C. FUNCTIONAL INSPECTION PARAMETERS

SR. SPECIFICATIONS / DESIRE / CHECK OK /
ASPECT REMARKS IF NOK
No. POINTS NOK
1 Genset on (start)/ off (stop) Check

2 Fuel leakages from joints Check all joints

2.1 IMV banjo bolt

2.2 All joints of hp pipes

2.3 Injector side

3 Oil leakages (visual)

3.1 Cam cover seal

3.2 Injector seal

Front cover seal inlet and exhaust
3.3
side
3.5
Oil filter 'o' ring

3.6 Oil pressure switch

3.7 Oil cooler 'o'ring

3.8 Filter head to block

3.9 Dipstick 'o' ring

Cyl.head gasket inlet side and
3.10
exhaust side
3.12 Oil pan gasket

3.13 Oil drain plug

3.14 Cyl. block to bed plate

3.15 Crank sensor

4 Coolant leakages Check all joints (visual)

4.1 From hoses

4.2 From water pump

Intake & Exhaust gas leakages

5 TC to radiator pipe both ends
(R006)
5.1 CAC to gas mixer pipe both ends

5.2 TC to bellow pipe both ends

5.3 Expansion Bellow joints

 CC/QA-ED/F013/ Rev 009 DATE –18.08.2016
GENSET FINAL CHECK
SHEET
Prepared by : QA engineer Approved by : HOD QA

5.4 Silencer side pipe joints

6 Overhead lamp availability / functioning

write down the load ampere of

7 110 % load testing for % mints Ok/NOK = AMP
panel

Noise: Max 75 db (Standard Refer : IS 8528)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Avg

Vibration:
Above AVM on engine Below AVM at Engine Above AVM on Alternator Below AVM at Alternator
INTAKE TC INTAKE TC INTAKE TC INTAKE TC

D.CUSTOMER SPECIFIC REQUIREMENT : Caterpillar India Private Limited

OK / REMARKS SPECIFICATION/DESIRE CHECK OK/NO REMARK IF
SPECIFICATIONS / DESIRE / CHECK POINTS NOK IF NOK POINT K NOT OK
A) canopy aesthetic look C) No Cooper and Supplier branding allow
1 No dent (Small or Big) allow on canopy 1 Canopy sticker

2 No porous paint allow 2 Radiator sticker

3 Uneven paint thickness not allow 3 Control Panel sticker

4 No scratch mark allow 4 Controller

Main Alternator name plate
5 No uneven door gap allow for all canopy door 5
& sticker
6 Door hings should be inline with each other 6 AVM sticker

7 No rusty bolts allow 7 Air filter unit sticker

B) Sticker provision 8 Air filter element

1 Fgw name plate- 1 nos 9 Oil filter printing

2 Genset rating – 2 nos 10 Fuel filter printing

3 Fuel filling – 1 nos 11 Circuit Diagram (cooper)

4 Oil drain – 1 nos 12 Engine Ok sticker

Sticker electrical hazard & manual – 1 nos
5 13 Wiring harness sticker

6 Sticker hot surface – 1 nos 14 Power cable sticker

7 Sticker earthing – 2 nos 15 Battery cables sticker

8 Sticker lifting – 4 nos

9 Sticker fgw logo small -3 nos

10 Engine rocker cover plate – 1 nos

11 Sticker emergency – 1 nos

12 Sticker glycol mix coolant- 1 nos

 CC/QA-ED/F013/ Rev 009 DATE –18.08.2016
GENSET FINAL CHECK
SHEET
Prepared by : QA engineer Approved by : HOD QA

All machining parts should be painted with black paint (rev 04)

Engine Parts affected OK / NOT OK REMARKS IF NOT OK

Machining area near oil cooler
Core plug boss machining area
FIP mounting area (GCC)
Feed pump mtg.area
Above Intake Manifold
Engine Mounting bracket
All Machining bosses of cyl bock
Machined bosses on Cylinder head
Above Exhaust Manifold & bush
Starter Intermediate Plate
Engine and alternator coupling hub
Belt tensioner Bracket
Crank Pulley
Idler pulley
Water pump pulley
Fan pulley
EGR Valve body
Turbo housing
Exhaust Manifold
Alternator shaft rust trace mark
Spacer between EGR Valve & EGR Cooler
Charging alternator body(Alum)
Cover Oil Cooler body (Alum)
Punching area on Cyl block.
Canopy parts affected
Base frame Rusty
Door rusting
Rust below lifting hook
Rusty at canopy wall & corners
Lock pin rusty
Lock rusty

E- ADDITIONAL CHECKPOINTS (rev 08 Point. no. 7& 8 Added)

SR. NO. ASPECT/ CHECK POINT OK / NOT OK IF NOT OK ACTION TAKEN

1 Misalignment of cac piping & cooling pipe with radiator.

2 Misalignment of intake & exhaust system

3 Control panel door cracking at MCB pocket

 CC/QA-ED/F013/ Rev 009 DATE –18.08.2016
GENSET FINAL CHECK
SHEET
Prepared by : QA engineer Approved by : HOD QA

4 Alternator shaft rusty check

5 Ensure Metallic pin used On -Off KEY switch to be fitted to Control Panel

Fuel float working / connection check (Compact-G25891507010 Regular-

6
G258007030002)

7 Transfer pipe Coolant Hose fouling with Exhaust Elbow 2 Cylinder

8 Water pump shaft failure , Fan pulley come out

9 Control panel door lock fitment/working

10 Coolant drops observed inside canopy (Near cooling system)

PARAMETER READINGS (SCOPE OF DG TESTING) (R007)

SR.NO. SPECIFICATIONS / DESIRE / CHECK POINTS VALUE REMARK IF NOT OK

FUEL LEVEL - If Applicable

1
(NOTE: LFL :-SHUT DOWN 5 %)
BATTERY VOLTAGE (at charging )-
2
(NOTE:12V BATTERY :-UPTO 14.2V MAX & 24 V :- 27.5 V MAX)

3 WORKING OF AMF FUNCTION - If Applicable

4 CONTACTORS WORKING- If Applicable

5 COLD ADVANCE SOLENOID OPERATION (UP TO 55°C) If Applicable

CHARGING ALTERNATOR OUPUT – DC VOLTAGE & ALT WL CONNECTIONS FOR CRG
6
ALTERNATOR
BATTERY CHARGER VOLTAGE – FOR 12 VOLT – REQUIRE 14.2 V & FOR 24 VOLT RE-
7
QUIRE 27.5 V