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Care Of The Diesel Fuel Tank
Fill the fuel tank at the end of the day, because the incoming fuel will drive out the moisture-laden air and prevent condensation. The strainer in the fuel tank filler opening should be removed and cleaned regularly.Draining Fuel Tank Sediment Accumulation
Open the drain cock and drain off any sediment or water which may accumulate in the fuel tank before starting the engine. In temperatures below freezing, drain shortly after the engine has stopped to prevent water freezing in the bottom of the tank and other low points in the system.Fuel Filtering System
As either the primary fuel filter element or the final fuel filter element gradually become clogged with foreign material, lack of horsepower will be noticed and the position of the fuel gauge indicator will work back from the original position in the NORMAL (green or approximately 30 PSI) range to the OUT (red or approximately 20 PSI) range. Every 250 hours or when the indicator shows in the OUT (red) range, the metallic primary fuel filter element (if equipped) should be removed and washed. If the indicator still shows in the OUT (red) range, the final filter element should be replaced with a Caterpillar filter element. Other make fuel filters may not meet filtering or capacity requirements. See the topics, PRIMARY FUEL FILTER and FINAL FUEL FILTER.Primary Fuel Filter (Optional)
To remove the filter element, stop the engine and shut off the diesel fuel tank valve. Loosen the nut on the filter cover and lower the filter case. Remove the element and wash in clean solvent or diesel fuel. Reinstall the element. Final Fuel Filter
The filter element collects and holds contaminants and cannot be washed or otherwise restored.To remove the used filter, proceed as follows:1. Stop the engine and close the diesel fuel line valve (if equipped).2. Unscrew and remove filter. 3. Clean the gasket sealing surfaces on the filter bases. 4. Lubricate the new filter gasket with clean diesel fuel.
Do not pour fuel into the new filter element before installing. Prime the system as instructed in the topic, PRIMING THE FUEL SYSTEM.
5. Tighten the filter by hand until the gasket contacts the base, then tighten 1/2 to 3/4 turn more.6. Start the engine and run at 1000 rpm for several minutes and check for leaks. If the engine fails to start, prime the fuel system. See the topic TO PRIME THE SYSTEM. Keep New Fuel Filters On Hand
Extra filters should be kept on hand for replacement. Always keep filters wrapped in their original carton to insure against dust and dirt accumulation which will shorten the life of the filters or may cause damage to the fuel injection equipment.To Prime The System
If air is trapped in the fuel system, the diesel engine will either not start, or will misfire. Then it is necessary to prime the system.The fuel priming pump is mounted on the fuel filter base. If the fuel filter is changed or if the engine has run out of fuel, prime the fuel system as follows: 1. Be sure the fuel line valve is open and the engine shutoff control is off.2. Unlock the fuel priming pump.3. Operate priming pump until increased resistance is felt.4. Lock fuel priming pump.If the engine fails to start or continues to misfire or smoke, further bleeding is necessary. With engine running, or with the use of the priming pump, loosen fuel line nuts, one at a time, several times in succession and allow fuel to run until free of air bubbles. Tighten fuel line nuts.
LOOSENING FUEL INJECTION LINE TO BLEED SYSTEMFuel Injection Equipment
When improper fuel injection is affecting engine operation, a systematic check should be made to determine the cause. The most likely cause is dirt or water in the fuel. Drain the sediment from the fuel tank. Check the fuel pressure gauge as mentioned in the topic, FUEL FILTERING SYSTEM. Replace the filters if necessary. Then prime the fuel system until clean fuel reaches the fuel injection pumps. If the fuel system is air bound, priming the system will overcome the difficulty.If the engine is running irregularly, smoking, or knocking, a fuel injection valve may not be spraying the fuel properly.Direct Injection System
The fuel system of direct injection engines is essentially the same as precombustion chamber engines. The absence of the precombustion chamber requires a different fuel nozzle and adapter. Externally the direct injection fuel nozzle resembles the precombustion chamber nozzle except it is longer in length. Nozzle testing and replacement procedure is the same as illustrated for the precombustion chamber engines, except that an extracting tool is used to remove the fuel nozzle and adapter. The seal on the adapter should be inspected and replaced if damage.Precombustion Chamber Injection System
Testing Fuel Injection Valves
Whenever an engine performs in such a manner that a fuel injection valve is suspected of causing trouble, test all fuel injection valves. To test the injection valves: Loosen the fuel injection line nut at the fuel injection pumps, one at a time, while the engine is running. When a nut is loosened and the exhaust smoking is completely or partially eliminated and the irregularity in running is not affected, this identifies the probable location of a defective valve and a new one should be installed in that cylinder to definitely determine if the valve removed was defective. Never wire brush or scrape a fuel injection nozzle assembly as this will damage the finely machined orifice. Your authorized dealer has the proper tools for cleaning and testing fuel injection valves.
LOOSENING FUEL INJECTION LINE NUT TO TEST VALVE Before removing your fuel injection nozzle assembly, Caterpillar recommends that you contact your Caterpillar dealer for more detailed information.Remove Fuel Injection Valve
Clean dirt from around the valve cover and remove. Before removing an injection valve, clean the dirt from around the valve and line connections. Disconnect the lead wire from the glow plugs. (If so equipped)Loosen the fuel injection line at the valve housing and disconnect it from the valve. Immediately install plugs to