F U E L S Y S T E M S

Fuel Contamination ControlDirty fuel is your engine’s worst enemy.

Fuel system components are more sensitive than ever to fuelcontaminants. You can maintain performance and extendcomponent life by carefully managing your fuel-relatedoperations and procedures.

This unseen villain can rob your engine of power,accelerate wear of sensitive fuel system components and reduce fuel efficiency. Keeping your fuel and your fuel system clean should be a top priority,especially in construction, mining, and other dustyapplications where higher horsepower engines are inuse. With the higher injection pressures and closertolerances of today’s diesel engines, clean fuel deliversmaximum performance, productivity and service life.

One critical element in any fuel contamination controlprogram is Cat® High Efficiency Fuel Filters. They’respecially designed for today’s diesels, using a super-finefiltration media for maximum filtration.

Fuel Contamination Control

Why clean fuel is so important

As little as one spoonful of dirtin a tank of fuel can ruin a fuelinjector in only eight hours.

In the fuelA reliable fuel supplier is your best defenseagainst source contamination. Demandperiodic sampling and testing to assure theconsistent quality you need for topperformance.

During operationIn dusty applications such as construction andmining, airborne contaminants can be drawninto your fuel tank through the vent tube.Likewise, a vent in the fuel tank cap can ingestdust if it is not properly sealed. Contaminantscan also develop during storage or enter thesystem through improper fuel transfer.

During serviceAny time your fuel system is open, whether it is to change filters, make repairs or forrefueling, contaminants can enter the system.

Sources of fuel contamination

Out of sight is not out of mind

®

The most controllable contaminants areabrasive particulates, which can vary greatly insize, hardness and abrasion. The comparisonillustrated here demonstrates the very tightclearances in your fuel system and the size ofvisible particles. As you can see, even particlesthat aren’t visible can wear away at your fuelsystem and reduce performance.

Human hair (80 microns)

HE filtration(2 microns)

Standard filtration(15 microns)

Damages fuel systems(5-10 microns)

Fuel contamination is, and always has been, a concern with all types of Cat Diesel Engines.It has become even more important in recentyears as engineers have worked to make dieselengines more economical and environmentallyfriendly. As emissions and fuel consumptionhave decreased, injection pressures andtolerances between components haveincreased. Higher RPMs submit precisioncomponents to even more potential wear and abrasion.

Today’s Cat Engines deliver more horsepower,better response and better fuel economy thanever. They are also more susceptible to wearand damage from fuel system contaminants.Damage can be caused by anything in yourfuel system that should not be there, includingparticles, heat, water and air bubbles. Togetheror alone these contaminants can drain powerfrom your engine, accelerate component wearand eventually lead to a breakdown.

F U E L S Y S T E M S

Abrasive contaminants accelerate wear as theymove through the fuel system at very highvelocities. In some cases, the contaminants inthe fuel may be as abrasive as the materialsused to machine parts in manufacturing.

Contamination can cause problems throughoutthe fuel system, but there are two areas that areespecially susceptible to wear and damage.

Injector Plunger and BarrelMinimum clearances of 2.5 microns make it critical to maintain a fluid film between theserapidly moving parts. Microscopic abrasiveparticles cause scratching, which can eventuallylead to scuffing, metal-to-metal contact andinjector seizure.

Control ValvesLocated throughout the fuel systems, thesevalves control fuel pressure. Contaminants canerode the mating parts of the valves, causingthem to leak and perform below specifications.A loss of engine power is the result.

Standard Typical High Efficiency15 Micron Absolute Engine Application 2 Micron Absolute

Part Number Part Number

1R-0712 3176, 3400 1R-0749(3176, 3400 Injector)

1R-0715 3500 Machine 1R-07551R-0718 3500 Stationary 1R-0756*1R-0740** 3116 MUI Truck 1R-0750

3200, 33001R-0740** 3114, 3116, 3126 1R-07591R-0740** 3116 EXC. 1R-0753***1R-0740** 3126 Injector-MUI Truck, 1R-0751

Marine and Industrial

Get maximum protection with Cat High Efficiency Fuel Filters

*Cartridge **Temporarily covered by 1P2299 ***Approximately 50 percent more capacity for 320 and 325 Excavator

Where contaminants do their damage

Cat High Efficiency Fuel Filters are speciallydesigned for the higher injection pressures andprecision components of today’s engines. They usean exclusively designed filtration media to removemore than 98 percent of particles 2 microns andlarger. More contaminants are removed, maximizingprotection of injectors, pumps and other fuel system components.

From top to bottom, Cat High Efficiency Fuel Filters are engineered for performance. Features like spiral roving and acrylic beads maintain pleatstability and spacing for maximum efficiency andcapacity. The non-metallic center tube is strongerand prevents metal contamination. The self-lubricating, free-rotating seal prevents bunching and eliminates leaks.

Talk to your Cat Dealer about how you can benefit with High Efficiency Fuel Filters.

98% efficiency

• = 2 micron particle

Cat filters Competitors’ filters

50% efficiency

PEHP7046 © 1997 Caterpillar Printed in U.S.A.

F U E L S Y S T E M S®

During storage and transferWithout proper storage and handling procedures,even the cleanest fuel can deteriorate or becomecontaminated. Here are steps you can take to keep sediment, dirt and environmentalcontaminants out of your fuel system.

❏ Periodically drain and flush all fuel storagecontainers, including tanker trucks andstationary tanks. This will remove sedimentsthat can easily enter the fuel stream.

❏ Keep all fuel nozzles, hoses and otherequipment clean.

❏ If a nozzle is dirty, clean it thoroughly beforefueling.

❏ Maintain all hoses, gaskets and seals in yourfuel storage and transfer equipment.

❏ Use line filters on all fuel transfer equipment.❏ Never transfer fuel with buckets, funnels or

other open containers.❏ Only purchase fuel from a reliable, reputable

source. Demand periodic testing to assure youare getting a consistently high-quality product.

During operationFighting fuel contamination is a full-timeconcern for everyone from the machineoperator to maintenance technicians. This checklist should be a part of any daily inspection program.

❏ Repair any fuel line leaks immediately. If fuel is leaking out, contaminants can alsoget in.

❏ Never operate a machine without theproperly installed fuel cap.

❏ If a fuel cap does not seal properly due todeteriorated gaskets or other damage, replaceit immediately.

❏ Make sure fuel tank vent tubes are open andfunctioning properly.

❏ Do not run machines to the point when thefuel tank is completely empty. Doing so candraw sediment from the bottom of the tankinto the fuel system.

❏ Alert maintenance and service techniciansimmediately of any unexplained power loss,excessive smoke or hard starting, especiallywhen the engine is warm.

During service and maintenanceMany fuel system failures occur immediatelyafter the engine has been serviced. Planning and preparation are the keys to keepingcontaminants out of your engine when it is“open” for service or repairs.

When changing filters❏ Maximize filtration protection with Cat High

Efficiency Fuel Filters. The moderate costdifference is made up in greater protection.

❏ Follow the recommended filter changeschedule. If premature filter plugging occurs,consider your fuel quality and othercontamination sources.

❏ Remove filters carefully, making sure not toknock dirt and debris from the enginecompartment into openings.

❏ Keep filters packed in their original box untilthey are installed.

❏ Never pre-fill a new filter — doing so allowssome fuel to bypass the filter altogether.

When performing engine service❏ Clean dirt, dust and other debris from the

engine compartment before removing filtersand other fuel system components.

❏ Use a high pressure wash to blast mud, dust,dirt and other built-up grime off the enginebefore “opening” the engine for repairs.

❏ Tightly cap or plug all openings duringrepairs, even if they are needed only for afew minutes.

❏ Clean reusable parts with solvents usingproper cleaning and drying methods.

❏ Never place components directly on theground.

❏ Keep new parts in their original package until needed.

❏ Don’t reuse seals, replace them.❏ Perform routine inspection of fuel line

connections from the tank to the fuel pump.❏ Maintain a regular schedule for draining

machine fuel tanks: weekly for severelydusty conditions, every three months fornormal conditions.

Your Cat Dealer has answers

Whether you need Cat High Efficiency FuelFilters, preventive maintenance services ordiagnostic services, your Cat Dealer is alwaysyour best source. No one knows your fuel system better, and no one else can offer the levelof expertise you need to minimize costs andmaximize productivity. Call today for details.

How to minimize fuel system contamination