3054 and 3056 Industrial and Generator Set Engines Caterpillar

Remove Air From The Fuel System (S/N: 4ZK; 6FK)

If air enters the fuel system, the air must be purged before the engine can be started.

Air can enter the fuel system when any of the following events occur:

• The fuel tank is drained during normal operation.

• The low pressure fuel lines are disconnected.

• A part of the low pressure fuel system leaks during engine operation.

• The fuel filter is replaced.

Use the following procedure in order to remove air from the fuel system.

Illustration 1	g00310668
(1) Vent plug (2) Fuel filter base

1. Loosen the vent plug (1) on top of fuel filter base (2).
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   Illustration 2	g00310703
   (3) Fuel transfer pump

2. Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the vent plug. Tighten the vent plug.

   Note: If the drive cam of the fuel transfer pump is at maximum lift, the priming lever cannot be operated. The crankshaft must be rotated one revolution.

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   Illustration 3	g00310743
   (4) Nut for the fuel line to the air inlet heater

3. If the fuel line for the air inlet heater has been drained, loosen the nut for the fuel line to the air inlet heater (4). Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the fuel line. Tighten the nut for the fuel line to the air inlet heater (4) to a torque of 22 N·m (16 lb ft).
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   Illustration 4	g00310824
   (5) Nuts for the fuel line to the fuel injection nozzles

4. Air from the fuel lines is also removed by loosening the nuts for the fuel line to the fuel injection nozzle (5). Operate the starting motor until the fuel, which is free of air, flows from the fuel line. Tighten the nuts for the fuel line to the fuel injection nozzle (5) to a torque of 22 N·m (16 lb ft).

Remove Air From The Fuel System (S/N: 7AK; 1ML)

Illustration 5	g00560109
(1) Bolt (2) Fuel line fitting

If air enters the fuel system, the air must be purged before the engine can be started.

1. Loosen bolt (1) on fuel line fitting (2).
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   Illustration 6	g00310703
   (3) Fuel transfer pump

2. Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the fuel line fitting. Tighten the bolt (1).

   Note: If the drive cam of the fuel transfer pump is in the position of maximum cam lift, the priming lever will not operate. The crankshaft must be rotated one revolution.

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   Illustration 7	g00560113
   (4) Fuel line nut

3. The manual stop control (if equipped) must be in the run position. If an electrical stop control is used, the ignition key must be in the run position.

4. Loosen the fuel line nut (4). Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the fitting. Tighten the nut for the fuel line (4) to a torque of 22 N·m (16 lb ft).
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   Illustration 8	g00560115
   (5) Fuel line nuts

5. Loosen the fuel line nuts for two of the fuel injection nozzles.

6. The manual stop control (if equipped) must be in the run position. Operate the starting motor until the fuel, which is free of air, flows from the fuel line.

7. Tighten the nuts for the fuel lines (5) to a torque of 22 N·m (16 lb ft).

8. The engine is now ready to start. Operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system. Running the engine for this period of time will help ensure that the pump is completely free of air. Damage to the internal parts of the pump which is caused by metal to metal contact will be prevented. The fuel system may need to be primed or the fuel system may have a fuel leak if the following conditions exist:

   • The engine will not start.

   • The engine continues to misfire.

   • The engine smokes.

Remove Air From The Fuel System (S/N: 5YS; 7MS; 2PW; 3GW)

If air enters the fuel system, the air must be purged before the engine can be started. Air can enter the system when the following events occur:

• The fuel tank is empty or the tank has been partially drained.

• The low pressure fuel lines are disconnected.

• A leak exists in the low pressure fuel system.

• The fuel filter is replaced.

Use the following procedure in order to remove air from the fuel system:

1. Vent air from the primary fuel filter and from the secondary fuel filter.
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   Illustration 9	g00310885
   Primary fuel filter, secondary fuel filter, and fuel filter base (Bosch and Delphi fuel systems) (1) Vent plug (2) Fuel filter base

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   Illustration 10	g00310703
   (3) Fuel transfer pump

   1. Bosch and Delphi fuel systems.

      Loosen the vent plug (1) on top of the fuel filter base. Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the vent plug. Tighten the vent plug.

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      Illustration 11	g00310963
      Fuel filter assemblies (Stanadyne fuel system) (1) Vent plug for the primary fuel filter (2) Vent plug for the secondary fuel filter

   2. Stanadyne fuel system

      Loosen the vent plug (1) on top of the primary fuel filter base. Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the vent plug. Tighten the vent plug.

      Loosen the vent plug (2) on top of the secondary fuel filter. Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the vent plug. Tighten the vent plug.

      Note: If the drive cam of the fuel transfer pump is in the position of maximum cam lift, the priming lever will not operate. The crankshaft must be rotated one revolution.

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   Illustration 12	g00311106
   (4) Nut for the fuel line to the air inlet heater

2. If the fuel line for the air inlet heater has been drained, loosen the nut for the fuel line to the air inlet heater (4). Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the fuel line. Tighten the nut for the fuel line to the air inlet heater (4) to a torque of 22 N·m (16 lb ft).
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   Illustration 13	g00311183
   (5) Nuts for the fuel line to the fuel injection nozzles

3. Loosen the connections for the high pressure fuel lines on two fuel injection nozzles. Operate the starting motor until fuel, which is free of air, flows from the fuel line. Tighten the nuts for the fuel line to the fuel injection nozzles (5) to a torque of 22 N·m (16 lb ft).

   Note: Damage to the fuel injection pump, to the battery, and to the starter motor can occur if the starter motor is used excessively to purge the air from the fuel system.

4. The engine is now ready to start. If the engine stops or if the engine runs roughly, check for air in the fuel system. If air is in the fuel system, leakage in the low pressure fuel system probably exists.

   Note: Operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system. Running the engine for this period of time will help ensure that the pump is completely free of air. Damage to the internal parts of the pump, which is caused by metal to metal contact, will be prevented.