DEALER BEST PRACTICE SERIES

Series High Efficiency Fuel

Filters
Component
Site Component MARC
Application Maintenance Life Safety
Management Rebuild Management
Management

Series High Efficiency Fuel Filters ............................. 0

1.0 Introduction ........................................................ 1
2.0 Best Practice Description ................................... 1
3.0 Implementation Steps ........................................ 3
4.0 Benefits.............................................................. 3
5.0 Resources Required .......................................... 3
6.0 Supporting Attachments / References ............... 3
7.0 Related Best Practices ...................................... 4
8.0 Acknowledgements............................................ 4

DISCLAIMER: The information and potential benefits included in this document are based upon information provided by
®
one or more Cat dealers, and such dealer(s) opinion of “Best Practices”. Caterpillar makes no representation or warranty
about the information contained in this document or the products referenced herein. Caterpillar welcomes additional “Best
Practice” recommendations from our dealer network.

February 15
0107-2.1-1051
CAT GLOBAL MINING DEALER BEST PRACTICE SERIES

1.0 Introduction

Modern high-pressure, electronically controlled fuel systems are used on nearly all Caterpillar
engines. These systems deliver better performance and improved fuel economy over older
mechanical systems. In general, electronic injectors should last until engine overhaul if relatively
clean fuel is used along with high quality, high efficiency fuel filters.

However, because modern injectors produce higher injection pressures, (typically 25,000 –
30,000 psi) they are subject to accelerated wear from abrasive particles in the fuel. Using fuel
with high levels of particulate contaminants or continuing to operate the machine after the
plugged fuel filter light has been activated can cause rapid injector wear.

New and damaged injector poppet

vales. Abrasive debris flowing at
very high velocity across the poppet
seat causes erosion damage and
internal injector leakage.

Adding an additional fuel filter in series with the standard fuel filter can significantly improve
injector life.

2.0 Best Practice Description

3500 Series engines use two 4-micron fuel filters in parallel to provide adequate debris holding
capacity. This arrangement provides single pass filtration, which is adequate if:
• The fuel is reasonably clean
• Fuel filters are changed before or immediately after the plugged filter light comes on

The filter media (paper) in the filter, which actually traps and holds the particulate debris, is
capable of single pass efficiency in excess of 98%. However, as the debris holding capacity of the
media is reached, flow restriction through the media increases and the fuel pressure drop across
the media starts to increase. This pressure difference between the inlet and outlet sides of the
filter is commonly referred to as “delta p.” Filter efficiency typically remains high until the filter
reaches about 18 – 20 psi delta p. At this point, the pressure differential exceeds the ability of the
media to hold trapped debris particles and begins to push debris through the filter media. As delta
p increases, the size and number of particles pushed through the media increases sharply. These
particles cause injector abrasive wear and loss of performance.

THE INFORMATION HEREIN MAY NOT BE COPIED OR TRANSMITTED TO OTHERS WITHOUT THE WRITTEN PERMISSION OF CATERPILLAR

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Additional
series filter

Standard
parallel filters

Typical 3500 Series Fuel System with Series Filter Added

Below 18 psi pressure drop, high efficiency fuel filters capture and retain nearly 100% of abrasive
particles. Pressure drops in excess of 18 psi force debris particles through the filter media and
downstream. As restriction increases, the size and number of particles forced through the filter
media increases dramatically.

Adding an additional (series) filter downstream of the factory parallel filters traps particles, which
may otherwise be pushed through the media. Most 3500 engines will operate without noticeable
THE INFORMATION HEREIN MAY NOT BE COPIED OR TRANSMITTED TO OTHERS WITHOUT THE WRITTEN PERMISSION OF CATERPILLAR

DATE CHG
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performance loss to as low as 10 psi fuel pressure to the injectors. With a nominal fuel supply
pressure to the fuel filter of 65 psi, it is possible to achieve delta p in excess of 50 psi if the filter
becomes severely plugged. This will allow very large amounts of debris to reach the injectors if a
series filter is not used. Keep in mind that a series filter will not cause additional plugging, it will
simply catch debris pushed through the first filter.

3.0 Implementation Steps

Factory arrangements are not available. However, the series filter can be added by fabricating a
mounting bracket and hoses.

Series filter (center) installed downstream of the factory parallel filters (left)

4.0 Benefits

Installing series filtration can protect the injectors and help them last until engine overhaul. It is
not uncommon for applications with poor fuel quality to replace injectors at engine mid-life. On a
3516, the cost of mid-life injector replacement is $20,000 or more. Using series filtration can often
eliminate this cost.

5.0 Resources Required

• Additional High Efficiency filter and filter base
o Filter P/N 1R-0755 for 3500 Series engines
• Fabricated filter mounting bracket and hoses

6.0 Supporting Attachments / References

Improving Component Durability booklets

Specifically:
Fluid Cleanliness Management SEBF1020

THE INFORMATION HEREIN MAY NOT BE COPIED OR TRANSMITTED TO OTHERS WITHOUT THE WRITTEN PERMISSION OF CATERPILLAR

DATE CHG
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7.0 Related Best Practices

None.

8.0 Acknowledgements

This Best Practice was written by:

Dick Douglas
Market Consultant
Caterpillar Global Mining
Douglas_Richard_D@cat.com
1-309-675-5699

THE INFORMATION HEREIN MAY NOT BE COPIED OR TRANSMITTED TO OTHERS WITHOUT THE WRITTEN PERMISSION OF CATERPILLAR

DATE CHG
NO NUMBER
Series High Efficiency Fuel Filters 2/17/2015 0107-2.1-1051
03
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