Loss Of Fuel Prime Causing Hard Start Issues In Certain C15 Tier 4 Interim Generator Set Engines{1250, 1256} Caterpillar

Generator Set:

C15 GEN SET (S/N: T4A1-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problems

Some C15 Tier 4 Interim engines have experienced hard start issues because of loss of fuel prime. This issue has been observed mainly with generator sets that were exercised at intervals of more than one week. Fuel drains back to the tank resulting in air in the fuel lines and loss of prime at the transfer pump.

Solution

Do not perform this procedure until you read and understand the material this procedure contains. Table 1 contains the part numbers needed for this change.

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When servicing or repairing electric power generation equipment: Make sure the unit is either locked out or tagged DO NOT OPERATE. Remove all fuses. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged. Make sure residual voltage in the rotor, stator and the generator is discharged. Failure to do so could result in personal injury or death.

1. Lock out and tag out the generator.

   1. Open the generator set breaker.

   2. Engage the "STOP" button on the EMCP.

   3. Activate the "Emergency Stop".

   4. Isolate the AC auxiliary voltage for the following components :
      • Battery chargers

      • Coolant heaters

      • Generator space heater

   5. Disconnect the battery cable.

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Illustration 1	g03545458

2. Install check valve (6) .

   Note: When replacing fuel components, take measures not to introduce contamination into the fuel system. Contamination can lead to early component failure and improper component functionality.

   1. Install flared reducer (7) to the female end of check valve (6) .

   2. Install connector (8) to the male end of check valve (6) .

   3. Install check valve (6) with the adapters at the fuel supply line between the primary fuel filter and the fuel transfer pump.

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Illustration 2	g03428124

3. Install adapter (1) with o-ring seal (3) into the top port of the fuel regulator block.

4. Install check valve (4) with o-ring seal (5) into adapter (1) .

5. Install adapter (2) with o-ring seal (5) into check valve (4) .

6. Verify proper installation and component operation.

   1. Verify that the check valve is operating correctly.

   2. Ensure that there are not any fuel leaks present.

   3. Verify that there are not additional check valves installed other than the valves listed in this article.