3500 Generator Sets Fuel System Secondary Filter - Replace Caterpillar


Fuel System Secondary Filter - Replace
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1.1. Replacing the Fuel Filter Elements with the Engine Stopped
2.1. Replacing the Fuel Filter Elements During Engine Operation
3.2. Duplex Fuel Filters

Note: If the engine is equipped with duplex fuel filters, the fuel filter elements can be changed while the engine is in operation. Refer to "Replacing the Fuel Filter Elements During Engine Operation".

------ WARNING! ------

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare products.

Dispose of all fluids according to local regulations and mandates.



NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.


Replace the secondary fuel filter elements whenever the following conditions occur:

  • The fuel filter differential pressure gauge registers 103 kPa (15 psi).

  • The fuel filters have been used for 1000 service hours.

Replacing the Fuel Filter Elements with the Engine Stopped

  1. Stop the engine. Ensure that the engine will not start during this procedure.

  2. Shut off the fuel supply valve to the engine.


    Illustration 1g01411122
    (1) Bolts
    (2) Cover
    (3) Plug
    (4) Drain valve
    (5) Drain

  3. Connect a hose to drain (5). Place the other end of the hose into a suitable container in order to collect the fuel.

  4. Open drain valve (4). Remove plug (3). Allow the fuel to drain. Clean the plug and install the plug. Close the drain valve. Remove the hose from the drain.

    Note: Some fuel will remain in the housing after the fuel has been drained. This fuel will pour out of the housing when cover (2) is removed. Prepare to catch the fuel in a suitable container. Clean up any spilled fuel with absorbent towels or pillows. DO NOT use absorbent particles to clean up the fuel.

    ------ WARNING! ------

    Personal injury can result from parts and/or covers under spring pressure.

    Spring force will be released when covers are removed.

    Be prepared to hold spring loaded covers as the bolts are loosened.


  5. Be alert to the spring force. Gradually loosen but do not remove bolts (1). Before removing bolts (1), pry cover (2) loose in order to relieve any spring pressure. Remove cover (2). Remove the O-ring seal on the inside of the cover. Remove the fuel filter elements.

  6. Clean cover (2) and clean the O-ring seal. Clean the inside of the fuel filter housing.

  7. Install new fuel filter elements.

  8. Inspect the O-ring seal. Ensure that the surfaces for the O-ring seal are clean. Install a new O-ring seal if the old O-ring seal is damaged or deteriorated.

  9. Install cover (2). Ensure that the springs are seated properly between the cover and the fuel filter elements.

  10. Open the fuel supply valve. Reconnect the battery.

  11. Prime the fuel system. Refer to this Operation and Maintenance Manual, "Fuel System - Prime" topic (Maintenance Section).

Replacing the Fuel Filter Elements During Engine Operation

If the engine is equipped with duplex fuel filters, the fuel filters can be changed while the engine is in operation.

------ WARNING! ------

If the filter is changed during rapid air movement, an explosive vapor may be created. The explosive vapor may result in personal injury or in death.

If rapid air movement exists, stop the engine in order to change the filter.


------ WARNING! ------

Filter contains hot pressurized fluid when engine is running.

Follow instructions on control valve to avoid personal injury.


Duplex Fuel Filters



    Illustration 2g01463367
    (6) Control valve
    (7) Fill valve

  1. Open FILL valve (5) for a minimum of five minutes in order to fill the fuel filters that will not be serviced. The fuel filters that will not be serviced must be full of fuel. Close the FILL valve.

  2. If the main filter will be serviced, rotate control valve (4) to the "AUX RUN" position.

    If the auxiliary filters will be serviced, rotate control valve (4) to the "MAIN RUN" position.

  3. See "Replacing the Fuel Filter Elements with the Engine Stopped". Perform Step 3 through Step 9.

  4. Open fill valve (5) for a minimum of five minutes in order to fill the new elements. Close the fill valve.

    After the new filter elements are full of fuel, either the main filter or the auxiliary filter may be used.

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