Procedures for Increasing Component Life of Wheeled Excavator Fuel Systems{1250} Caterpillar

Excavator:

M313D (S/N: J3A1-UP; W3H1-UP)

M315D (S/N: J5B1-UP; W5M1-UP)

M316D (S/N: W6A1-UP; D6W1-UP)

M318D (S/N: W8P1-UP; D8W1-UP)

M322D (S/N: W2S1-UP; W2T1-UP; D2W1-UP)

Introduction

Modern fuel systems have been developed to improve engine performance while reducing emissions and providing fuel economy. Modern fuel systems operate at high pressures and as such, microscopic particles can damage the fuel system. Fuel system cleanliness is critical to the performance of C4.4and C6.6engines of Wheeled excavators.

The use of fuel containing contaminants and water has been reported to cause failure of fuel system parts and increased engine wear. Fuel injectors and fuel pump failures have also been reported as a result of using contaminated fuel.

Improving fuel quality and fuel cleanliness will increase engine performance, while decreasing fuel system damage and wear.

The information available in this document will help maximize machine performance. Owning and operating cost may be reduced by insuring your machine is using clean fuel and the latest improvements in fuel injectors and fuel pumps.

Using unclean fuel will cause the following:

• Reduced engine efficiency and durability

• Increased engine wear as a result of higher corrosion and engine deposits

• Lower fuel economy

• Shorten the time period between engine oil drain intervals causing more frequent oil drain servicing

• Accelerated wear to fuel system parts

• Premature component replacement

• Increased overall operating costs

Use the following procedures and guidelines to improve fuel quality.

Note: These guidelines and procedures do not lessen the machine owners and fuel suppliers responsibility to follow all industry standard practices for fuel handling and storage.

Procedure for Fuel Acquisition

Ensure that you are receiving clean fuel from your fuel supplier:

• Purchase fuel from a reputable supplier.

• Discuss your fuel concerns, needs, and requirements with your supplier.

• Discuss proper fuel safety, health, handling, and maintenance practices with your fuel supplier.

• Use fuel that meets or exceeds Caterpillar requirements for distillate diesel fuel

To help ensure optimum engine performance, a complete fuel analysis should be obtained before engine operation. The fuel analysis should include all of the properties that are listed in the Cat Specification for Distillate Fuel for Nonroad Diesel Engines, Table 1 found in Operation and Maintenance Manual, SEBU6251, "Cat Commercial Diesel Engine Fluids Recommendations".

Note: The diesel fuel cannot have any of the following: visually apparent sediment, suspended matter, or undissolved water.

Diesel Fuels that meet the "Cat Specification for Distillate Fuel for Nonroad Diesel Engines" will help provide maximum engine service life and performance.

Procedure to Ensure Clean Fuel is Pulled from In-ground Storage Tanks

Fuel free of contaminants and water is essential in order to achieve long injector life. The filtration systems on machines are not designed to clean heavily contaminated fuel. To ensure that clean, dry fuel is delivered to fuel tanks, use of bulk fuel filter coalesce systems is recommended. Coalesce filtration systems have been the standard method to clean large volumes of fuel in the airline and petroleum industries for more than 40 years. Filtration units use single pass filtration to remove solid particles and water from fuel. Filtration units are installed in the fuel supply line between the fuel storage tank and fueling station. The units are designed to meet the maximum flow requirements of the fuel delivery system and are the most cost effective and efficient method.

Note: The preferred method of fuel filtration is through filters with a rating of 20 microns absolute or less. Cat offers multiple sizes of bulk fuel filtration and water coalescing units that are recommended for ensuring the availability of clean dry fuel. Refer to Special Publication, PEHJ0156, "Cat Bulk Fuel Filtration Systems" and consult your Cat dealer for more information.

1. Filter the fuel coming into the bulk storage fuel tank.

2. Filter fuel at every subsequent transfer into and out of any container.

3. Drain water and sediment from the fuel storage tank weekly.

4. Drain water and sediment before the tank is refilled.

   A substantial portion of dirt and water can be removed from supply fuel by using proper storage tank settling and draining practices. Most remaining dirt and water can be removed by using bulk filtration or adding filtration and water separation capacity to each machine in the fleet.

Note: Wire mesh media (strainer-type filters) use is not recommended except for when standard media filters (cellulose or synthetic) are located downstream of wire mesh filters. Wire mesh filters typically have poor filtration efficiency and can corrode with time, thus allowing the passing of large particles. The use of water separators or a water coalesce devise is also recommended at points of fuel filtration.

Procedure to Filter Fuel Prior to Fueling Equipment Tanks

1. Filter the fuel at the last dispensing stage into the machine fuel tank through a filter with a rating of 4 microns absolute or less.

   Filtration should be located at the fuel dispenser to the machine fuel tank and downstream from any equipment such as transfer pumps. Transfer pumps and other equipment could potentially shed debris into the fluid stream.

Guidelines Regarding Fuel Cleanliness

1. Prior to fuel tank cap removal, clean around the fuel tank filler cap to remove dirt and debris. Cleaning this area prevents debris from entering the fuel tank.

2. Ensure that the fuel tank strainer is present before filling the tank.

3. Wash the strainer and the fuel tank cap with a clean and non-flammable solvent.

4. Prior to fueling the machine, use a towel that is clean and lint free to clean the fuel fill nozzle. Cleaning the nozzle before inserting the nozzle into the fuel tank will help prevent contamination of the fuel.

5. Keep fuel clean by always reinstalling the fuel cap after fueling, and by using clean tools when servicing fuel system components.

Procedure to Test Quality of Fuel

Determine if water and or contaminants are present in the fuel. The color of the fuel is not necessarily an indication of fuel quality. However, fuel that is black, brown, and/or similar to sludge can be an indication of the growth of bacteria or oil contamination.

1. Remove a sample of fuel from the bottom of the fuel tank.

2. Visually inspect the fuel sample for contaminants.

3. Check fuel API gravity with a 5P-2712 Thermometer/Hydrometer The acceptable range of the fuel API is 30 to 45 when the API is measured at 15° C (60° F).

4. Check the water separator. See below.

Note: Water separators may appear to be full of fuel when the water separator may actually be full of water. A full fuel tank minimizes the potential for condensation.

Procedure To Maintain Fuel Tank Cleanliness

Fuel quality is critical to engine performance and service life. Water in the fuel can cause excessive wear to the fuel system and can be introduced into the tank during fueling. Water condensation occurs during the heating and cooling of fuel. As fuel passes through the system, the fuel returns to the fuel tank causing water to accumulate in the tank.

Procedures for checking fuel tank cleanliness are as follows:

1. Drain Equipment Fuel Tank Sediment Daily

2. Check the fuel daily. Allow five minutes after the fuel tank has been filled before draining water and sediment from the fuel tank

3. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment.

   Note: A hose to drain the fuel tank is available behind the upper frame access door on the left-hand side of the machine.

4. Drain water and sediment into an approved container

5. Close the drain valve after draining the sediment from the fuel tank

   Note: Dispose of this waste according to all applicable regulations and mandates.

6. Only refuel after operating the engine in order to drive out moist air. Refueling the machine after operation helps prevent condensation.

7. Do not overfill the fuel tank. Fuel expands as temperatures increase and the tank may overflow.

8. Always change fuel filters at the recommended service interval in the OMM.

Note: Cat filters are designed and built to provide optimal performance and protection of the fuel system components.

Procedure to Drain the Fuel System Primary Filter/Water Separator Daily

1. Place a suitable container under the water separator in order to catch any fuel that might spill.

2. Open drain and allow the fluid to drain into the container.

3. Tighten drain by hand pressure only.

4. Dispose of the drained fluid according to all applicable regulations and mandates.

Guidelines for Servicing the Fuel System

Cleanliness is an important factor.

1. Prior to servicing the fuel filters, clean the areas around the filters prior to installation.

2. Before beginning the removal procedure, clean the exterior of the components thoroughly. Cleaning the components will help prevent dirt from entering the internal mechanism.

3. Always conduct a physical inspection on the used filter to ensure that filter is genuine, and clear of contaminants. Excessive contaminants imply poor fuel quality or lack of proper maintenance.

4. After replacing the fuel filters, use the following procedure in order to prime and to remove air from the fuel system.

   Note: "Never" pre-fill the filters while servicing. Fuel that is used to pre-fill the filter is not filtered. Contaminants present in the fuel will bypass the fuel filters and go directly into the fuel system. At high pressure, these contaminants will damage the fuel injectors and engine. Always use priming pump to prime the fuel.

Procedure for Fuel system priming and air removal

1. Ensure that the fuel system is in working order. Check that the fuel supply valve is in the "ON" position.

2. Operate the fuel priming pump 100 times.

3. Operate the engine starter and crank the engine.

4. After engine start, operate the engine at low idle for a minimum of five minutes, to ensure that the fuel system is free of air.

Note: After step 2 in the ""Procedure for Fuel system priming and air removal" ", the engine fuel system should be primed and the engine should be able to start.

Additional Information

At the time of this publication the fuel pumps and injectors with the latest improvements are listed below:

• 320-0680 Fuel Injector Gp

• 324-0532 Fuel Injection Pump Gp

• 317-8021 Fuel Injection Pump Gp

If the above steps do not provide adequate protection for the fuel system, Special Instruction, REHS7031, "Procedure to Install an Additional Fuel Filter for Certain Wheeled Excavators{0679,1261,1261}" has been published to document the installation of an additional fuel filter to the fuel system on M300D Wheeled Excavators.

Note: Installation of an additional filter will not resolve fuel cleanliness issues, addition of a filter will only prolong the service life of fuel system components

Reference Documents

In North America, use diesel fuels that meet the latest version of ASTM D975 Grades No. 1-D or No. 2-D (all listed sulfur levels).

In Europe, use diesel fuels that meet the latest version of European Standard EN590.

• Special Instruction, REHS3751, "Servicing the Outlet Check Plugs on the Fuel Injection Pump on C6.6 and C4.4 Engines"

• Service Magazine, SEPD1107, "Improved Servicing is Available for the Fuel Injection Pump for C6.6 and C4.4 Engines "

• Service Manual, SENR9969, "Troubleshoot C4.4 and C6.6 Industrial Engines and Engines for Caterpillar Built Machines "

• Operation and Maintenance Manual, SEBU8120, "Fuel System – Prime (C6.6)"

• Operation and Maintenance Manual, SEBU6251, "Cat Commercial Diesel Engine Fluids Recommendations"