- Generator Set
- 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)
- DG175-2 (S/N: KJ61-UP)
Introduction
This Special Instruction provides information regarding the procurement process of a service replacement engine as used in the Cat® DG Gaseous Generator Sets.
This process requirement is applicable to the 14.2L and 21.9L gaseous engines as utilized in the Caterpillar DG model generator sets.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
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.
Ensure that all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.
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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility. |
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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. |
Important Emissions Information
Certain engines are equipped from the factory with a catalytic converter and as such, are certified to meet U.S. Environmental Protection Agency (EPA) emission standards for stationary emergency engines.
The service information described herein must be followed exactly to ensure that the resulting configuration is certified to EPA standards and meets all applicable requirements.
Failure to correctly and completely follow these instructions may be a violation of EPA regulations subject to fines or other penalties as described in the Clean Air Act.
Adjusting the engine ignition timing to a non-specified value is prohibited. Compliance with the service instructions provided is required in order to maintain the EPA emissions certification.
Reimbursement
Use of this document does not authorize any reimbursement through Standard Warranty, ESC Warranty, or goodwill.
The confirmation of destruction process and/or the disposal process of the engine being replaced is not authorized for financial reimbursement through standard warranty, ESC Warranty, or goodwill.
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| Illustration 1 | g06362238 |
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Engine Replacement Form | |
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| Illustration 2 | g06362239 |
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Engine Destruction Confirmation Form | |
Information
A dealer shall comply with the instructions provided within the Cat DG Series Gaseous Engine Replacement Form (refer to Illustration 1) and Cat DG Series Gaseous Engine Destruction Confirmation Form (GEP005-2) (refer to Illustration 2) and any special instructions as given by the Electric Power Retail Product Support Representative or the engine manufacturer.
Cat DG Series Gaseous Engine Replacement Form and Cat DG Series Gaseous Engine Destruction Confirmation Form (GEP005-2) are included within this service publication.
Generator Sets located Within the U.S. and Canada:
Standard Warranty Period
The Cat dealer shall submit an Electric Power Retail Product Support inquiry to the primary North America Tier 2, to initiate the process.
The inquiry shall be formatted with the following information:
- Title: Cat DG Gas Engine Replacement Request Form
- Request Detail Description: Cat DG Gas Engine Replacement Request Form submitted for "Genset Serial Number"
- Attachment: Completed and Signed Engine Replacement Request Form, GEP005-2
Note: A completed and signed Replacement Engine Request form (GEP005-2) must be received for the request to be processed.
Non-Standard Warranty Period
- The Cat dealer shall contact the Caterpillar Service Parts group to procure a replacement long block engine.
- The Cat dealer shall submit a completed and signed Engine Replacement Request form to the Caterpillar Service Parts Analyst at the time the order is placed.
- Caterpillar Service Parts Analyst will forward the completed Form GEP005-2 to the Engine Supplier when the order is submitted.
Note: A completed and signed Replacement Engine Request form (GEP005-2) must be received for the request to be processed.
Generator Sets located Outside the U.S. and Canada:
Standard Warranty Period and Non-Standard Warranty Period
- The Cat dealer shall contact the Caterpillar Service Parts group to procure a replacement engine.
- The Cat dealer shall submit a completed and signed Engine Replacement Request form to the Caterpillar Service Parts Analyst at the time the order is placed. Caterpillar Part Analysts will forward the completed form GEP005-2 Rev A to the engine supplier when the order is submitted.
Note: A completed and signed Replacement Engine Request form (GEP005-2) must be received for the request to be processed.