Don't RUN a CAT out of fuel!!!!!!!!

HRS · 12-13-2010, 01:03 PM

Just finished a two day battle with a Fuel Filter/Water Separator change out on a 2001 Tradwinds. It was time to do routine PM on my 2001 Tradwinds 7390. I decided to do the oil change and while I was at it to do the Fuel filter change. I followed the directions in the CAT operators manual. That was the largest mistake that I have ever made. Spun the the old filter off and removed the separator bowl from the old filter, installed the O rings and applied diesel to the gaskets. Spun the filer on. I did not add any diesel to the filter per CATs instructions:

1. Stop the engine. Turn the ignition switch to the OFF position or
disconnect the battery. Refer to the Operation and Maintenance
Manual, “Battery or Battery Cable - Disconnect” topic (Maintenance
Section) for more information. Shut off the fuel supply valve (if
equipped).
2. Remove the used fuel filter and discard the used fuel filter.
3. Clean the gasket sealing surface of the fuel filter base. Ensure that
all of the old gasket is removed.
4. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
Do not fill the secondary fuel filter with fuel before installing.
The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause accelerated
wear to fuel system parts.
NOTICE
Due to specific requirements for Hydraulic Electronic
Unit Injectors, a 2 micron absolute high efficiency
fuel filter should be used. Recommended Caterpillar
fuel filters meet these requirements. Consult your
Caterpillar dealer for the proper part numbers.
5. Install the new fuel filter. Spin the fuel filter onto the fuel filter base
until the gasket contacts the base. Use the rotation index marks
on the filters as a guide for proper tightening. Tighten the filter for
an additional one turn (360 degrees) by hand. Do not overtighten
the filter.

Only a 10 minuet job. Stated the CAT and fires right up. It only ran less then a minuet. Lost prim and now I had to get the prim back. The setup on a 2001 Freightliner® XC Series is a CAT 330 with only one fuel Filter/Water separator and no way to manually prime the system. So I used the CAT instructions for :

Fuel Filter Bases that are Not Equipped with a Plug
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
1. Operate the starting motor. This will fill the fuel filter and the fuel
lines with fuel.
2. Once the engine starts, operate the engine at low idle. Do not raise
the engine speed above an idle, until the engine operates smoothly.

After 1 ½ days trying to get the prim back I called Freightliner 24 HR assistance and was told that I should have added diesel fuel to the filter.

Was told to add the fuel to the out side holes on the filter so that it would be filtered before it went to the injectors. After 20 or more attempts at starting the CAT it final fired and ran again.

Don't RUN a CAT out of fuel!!!!!!!!

Gary - K7GLD · 12-13-2010, 01:17 PM

Air in the filter is bad - air that then makes it's way into the injector lines is REAL bad...

Sometimes you have to actually loosen lines at the injectors to get the fuel to push out the air blocking fuel flow - not easy if the lines are hard to get to!

**JohnRR** · 12-13-2010, 01:24 PM

Quote:

Originally Posted by HRS

I did not add any diesel to the filter per CATs instructions:

Don't RUN a CAT out of fuel!!!!!!!!

That's a lesson you only want to learn once, pre filling the fuel filter with diesel fuel is the same for all diesel fuel filter changes.

Cat has always been a Bear to bleed the fuel system.

powderman · 12-13-2010, 01:29 PM

Quote:

Originally Posted by Gary - K7GLD

Air in the filter is bad - air that then makes it's way into the injector lines is REAL bad...

Sometimes you have to actually loosen lines at the injectors to get the fuel to push out the air blocking fuel flow - not easy if the lines are hard to get to!

The line pressure on my Cummins and if I read it correctly the 330 Cat is in excess of 20,000 psi. Loosening a line at that pressure is a good way to inflict serious injury.

**JohnRR** · 12-13-2010, 01:32 PM

Unfortunately that is part of the bleeding procedure.

bdpreece · 12-13-2010, 01:48 PM

There are many posts here and on the Cat RV Club site on changing the fuel filters and the warnings on an air lock. Bet you don't do it again.

Chuck 1935 · 12-13-2010, 05:55 PM

A heplful hint. Not many of us have extra diesel fuel laying around so how do you prime your filter with dirt free fuel. Simple, use a quart of transmission fluid. I promise it works and you know its clean. I always prime fuel filters and oil filters. It will save you problems.

HRS · 12-14-2010, 07:22 AM

I have a spar filter that I carry with us. I have now added a 1 Gallon can of clean diesel and a squirt bottle for pre filling the filter. That way if I have a filter problem on the road I can prime the filter and avoid the loss of prime. Thanks to all that have commented on my ordeal.

RustyJC · 12-14-2010, 07:35 AM

It's not just the Caterpillar. It's generally a pain to run ANY diesel out of fuel!

Rusty

Mopar1973Man · 12-14-2010, 07:39 AM

Noramlly when I'm priming the fuel system on my ISB Cummins you crack 1,3, and 4 and crank the engine till fuel spray is seen. (Not dribbling) and the tighten the lines and attempt to start 99% of the time this works...

Yes injection pressure is up there around 20K PSI... But I normally don't suggest messing with the injection system while you cranking on the engine.

**JohnRR** · 12-14-2010, 08:22 AM

Even with the higher pressure when you crank and crack the fittings open there's really not much of a chance for problem.

First have the fitting broken loose but still tight then while cranking the engine crack the fitting loose until fuel and air bubbles come out then in a very short period of time when it seems to be solid fuel tighten the line fitting. There's problem 3/4 of an inch of thread still holding the fitting on.

If memory serves me right on the older Cats you did the fitting after the pump then the fittings at the injector.

Retiredblade · 12-14-2010, 08:40 AM

From my days of operating Cat diesels, dozers, etc. despite what anyone says, fill them up to the brim, all fuel filters. I keep a 5 gal of diesel for just that purpose. Changed all my filters on my Islander and I fill everyone of them up, fuel, oil, cooling.

ditto · 12-14-2010, 10:29 AM

trick we learned at camp freighliner...home depot /lowes sell a rubber plug that fits the center hole of the fuel filter so the fuel being added to the filter flows

only to the out side "in comeing" holes and thus is filtered on way to engine! hope this helps..

bdpreece · 12-14-2010, 08:05 PM

Quote:

Originally Posted by ditto

trick we learned at camp freighliner...home depot /lowes sell a rubber plug that fits the center hole of the fuel filter so the fuel being added to the filter flows

only to the out side "in comeing" holes and thus is filtered on way to engine! hope this helps..

In what department do we find this rubber plug. Does it have a name or how do we describe it when asking for help locating it?