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The Tier III engine’s diesel fuel injection systems requires an extremely high fuel pressure—often over 25,000 psi—to function correctly. Without the high pressure, the burn pattern is not sufficient to produce the low contaminant emissions required by federal regulations.

Fuel systems tolerances between components have been reduced to assure that regulatory requirements are met. It is important to control contaminants in the fuel system to assure that all parts are working properly. Additional damage to the engine can occur due to contaminated fuel, and this type of damage may not be covered by warranty or may void the engine’s warranty.

Below are some helpful tips to keep contaminants from entering your fuel system.

• Do not pre-fill the fuel filters. Fuel used for this purpose is usually
contaminated and has not been filtered. It can damage critical fuel system parts. For Tier III engines, the filter must be kept clean and installed without pre-filling. Refer to your equipment manual for proper procedures, or use an electric fuel pump to fill the filter with filtered fuel.

• All maintenance procedures should be completed by a trained, qualified service technician. Case Power and Equipment’s technicians have been certified to service Tier III engines.

• The work environment must be sterile and free of airborne contaminants. A modern injector’s internal drillings are quite small and extremely susceptible to clogging. Any type of plugging in an injector can cause dribbling and, possibly, engine damage.

• The high pressure in the Tier III engine’s fuel injection systems operation can transform small particles of dirt, dust and rust into extremely abrasive contaminants that can severely damage components. Many modern injectors cannot be serviced but must be completely replaced if damaged.

• Do not use compressed air to clean dirt from fuel system fittings. Use an electrical contact cleaner or a spray parts cleaner. Keep exposed fuel system parts clean. Diesel fuel attracts airborne particles. The fitting frequently will have a residue where the work is being completed, even when there’s a small amount of fuel at the fitting.

• Many engines require secondary fuel filtration at a level of 3 microns. A filter’s micron rating indicates the size of the smallest particles that the filter will capture. Micron is an abbreviation for micrometer, one millionth of a meter. A human hair measures .003 mm/3/1000” in diameter. A micron measures 0.00004 mm/4/100,000”.

• Frequently clean all tools used for fuel system troubleshooting and repair. They may be overlooked as a possible source for contamination. Residual oil or fuel on the tools will attract airborne contaminants. Always clean tools before using them.

• Cap and plug fuel lines, fittings, and ports any time the fuel system is opened to help avoid contamination. Though the repair may only take a short time, airborne contaminants can drift in from an adjacent bay, through an inadvertent bump against the engine housing or off someone’s dirty clothing.

Additional Tips
Low Sulfur Fuel Requirements—It is always important to use the correct low sulfur fuel with your Tier III engine. Refer to your operator’s manuals to identify the sulfur requirements for all of your equipment.

Engine Maintenance—The fuel system components for the Tier III engines are much more expensive than those for the older engines, particularly the injection pumps. By following all recommended procedures for engine maintenance, the need for component replacement due to improper usage is unlikely, however.

Warranty Coverage Requirements—When procedures detailed in the operator’s manual have not been followed, and the manufacturer refuses to cover repairs under warranties, the equipment owner is liable for these repair expenses. Warranties will not cover damage from water, contamination, or use of incorrect fuel for injection pumps.

Check chain tanks, final drives, swing gear baths and gear boxes for water
Water will freeze during the winter, causing chains to break. Floating ice chunks will also harm gear boxes. Check each area for water at least once before the temperature falls below freezing.

Check freezing point of coolant
Make sure you’re using coolant that complies with ASTM standard D-621, with a freeze point low enough for your climate. If coolant freezes, it can crack the engine block and ruin the engine. For detailed information about coolant, read our coolant tips.

Add fuel conditioner
Fuel conditioner prevents your fuel from freezing and makes sure your engine starts in the cold. It’s like adding Heet to your car. The amount of conditioner required varies, based on the brand and model of the machine. Check the manufacturer’s recommendations. Make sure you match the fuel conditioner to the type of fuel you’re using (e.g., low sulfur).

Check the fuel filter
If the fuel filter is clogged, moisture can build up and freeze in the winter, causing your machine to run improperly or fail to start. Most filters have water traps that should be emptied before cold weather arrives. Keep an extra set of fuel filters in your cab to avoid downtime due to fuel problems.

Check cold start aids
Diesel engines spray ether into the air system to help the engine start in cold weather. For older machines that have ether spray bottles, check the bottle to make sure it contains a sufficient amount. For new machines with an automatic ether system, check to see whether it is functioning properly by visually inspecting the connections and hoses for cracks or loose connections.

Check for proper functionality of block heater
Block heaters keep fluids at the appropriate temperature and viscosity. If the block heater isn’t working, oil can thicken, making it harder to turn the engine over and adding stress on the battery. Check the block heater by plugging it in and touch the hoses to make sure they are warm.

Inspect lights, wipers, belts, cutting edges and back up alarms
It’s much easier to make repairs without needing to deal with the cold, snow and ice. Inspect your equipment thoroughly and take the time to test the lights, wipes, belts, cutting edges, back up alarms and anything that might be an inconvenience to fix during the winter.

Inspect air pre-cleaners
Large dust particles and debris can build up during the summer. If these particles are not removed, snow and ice could collect around them, allowing moisture into the air system, which could cause engine failure.

Check battery and connections
Corrosion around battery connections causes less voltage to be transmitted, and increases the strain on the battery. Corroded connections can drain the battery, preventing your machine from starting. Periodic inspections for corrosion could reduce the chance of being inconvenienced with a drained battery.