Fuel Pressure Gauge Test Kit is Now Available for Certain Generator Sets {0782} Caterpillar

Electric Power Generation

DG150 (S/N: T451-UP; NB91-UP)

DG30 (S/N: T361-UP; NBW1-UP)

Generator Set

DG100 (S/N: NB71-UP; T391-UP)

DG125 (S/N: T441-UP; NB81-UP)

DG175-1 (S/N: KL91-UP)

DG175-2 (S/N: KJ61-UP)

DG200-1 (S/N: KM31-UP)

DG200-2 (S/N: KJ71-UP)

DG230-1 (S/N: KM41-UP)

DG230-2 (S/N: KJ81-UP)

DG250-1 (S/N: KM51-UP)

DG250-2 (S/N: KJ91-UP)

DG275-1 (S/N: KM71-UP)

DG275-2 (S/N: KL41-UP)

DG300-1 (S/N: KJ41-UP)

DG300-2 (S/N: KJ21-UP)

DG350-1 (S/N: KM81-UP)

DG350-2 (S/N: KL61-UP)

DG400-1 (S/N: KM91-UP)

DG400-2 (S/N: KL81-UP)

DG450-1 (S/N: KJ51-UP)

DG450-2 (S/N: KJ31-UP)

DG60 (S/N: NB51-UP; T371-UP)

DG80 (S/N: NB61-UP; T381-UP)

New fuel pressure gauge test kit is now available for the products that are listed above. This document provides details regarding the use of the fuel pressure gauge test kit for DG series gaseous product Generator Sets.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.

Features and Improvements

Features of the dedicated sealed fuel pressure test port are listed below:

• Ease of use for the field technician.

• Consistency.

• Improved accuracy in measuring fuel pressure during commissioning and troubleshooting.

• Fuel system installer will no longer have to provide custom piping to provide a fuel pressure test port.

• Field technician will no longer have to remove the low fuel pressure sensor to gain access for installing a fuel pressure test port.

• Field technician will be able to identify easily and access the correct test point location, for measuring the required fuel pressure needed for the prime mover.

• The fuel system can be inspected by the Authority Having Jurisdiction (AHJ) prior to a field technician performing the start-up.

• The field technician cannot violate the fuel system inspection certificate.

• The new test port plug is a self-sealing port.

Required Parts

The required parts are listed in Table 1.

Note: Below 7.2° C (45.0° F) the neoprene core does not recover its original shape as rapidly as it would at temperatures above 7.2° C (45.0° F). Therefore, upon removal of the gauge adaptor (probe) used for pressure readings, the valves may not close fully and immediately or the valves may remain slightly open until the operating temperature is above 7.2° C (45.0° F). Duration of gauge adaptor (probe) insertion and pressure are also factors in the rate of valve closing. For this reason, the test port (plugs) should not be used in applications where discharging gas or liquids would create a hazard.

Note: The cap is equipped with a gasket to eliminate the small amount of leakage that may occur at lower temperatures after probe insertion and removal. The cap should be left on the test port (plug) always and tightened to deter unauthorized removal.

Note: Special care should be taken to assure that readings are taken in the shortest space of time and that a gauge adaptor (probe) is never left in a test port (plug) for a time period more than eight hours. Severe deformation of the valve may occur if the probe is left in the plug for a longer period of time.

Fuel Pressure Gauge Inspection

Inspect the fuel pressure gauge for any deformation prior to perform the fuel pressure test procedure:

• Cracked or damaged fuel pressure gauge cover.

• Fuel pressure needle is not working correctly or not working at all.

• Hose is cut, cracked and/or dry rotting.

• A bent or cracked probe.

• Damaged threads.

• Damage to the barbed hose adaptor.

Fuel Pressure Test Procedure

Perform the below procedure for measuring the fuel Pressure:

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Illustration 1	g06308982
Fuel Pressure Test Port

1. Fuel pressure test port is located on the fuel regulator assembly. Refer to Illustration 1.

2. Loosen the fuel pressure test port cap.

3. Slowly remove the test port cap from the test port plug.

4. Ensure that the fuel is not leaking from the test port plug once the cap has been removed (Audible, Smell, Sniffer). If the fuel leaks, immediately reinstall the test port cap and replace the test port plug.

5. If the test port plug does not have a fuel leak, remove the cap. The test port plug cap should be tethered to the test port plug. If the tether is missing or broken, replace the test port plug.

6. Remove the gauge adaptor cover. Clean and lubricate the gauge adaptor probe with required quantity of petroleum jelly or silicone grease.

7. Examine the gauge adaptor probe for any sharp burrs, which could cut the test port plug valve. Do not use a non-standard or damaged gauge adaptor probe.

8. Examine the gauge adaptor probe access opening in the test port plug, remove any contaminants. The test port plug access opening must be kept free of any contaminants.

9. Remove the test port plug cap and then fully insert the gauge adaptor probe. Secure the probe into place to prevent movement or becoming dislodged.

10. Read the displayed fuel pressure from the analog fuel pressure gauge.

11. Once the evaluation period has been completed, remove the fuel pressure gauge probe and securely install the test port plug cap.

Note: Do not leave the probe in the plug any longer than necessary.

Note: Longer the probe is inserted, the longer time it will take for the test port plug to seal when the probe is removed and if the probe is inadvertently left installed, the fuel pressure and operating temperature could cause the probe to be "ejected".