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Cat 12 D318 Won't Start

Cat 12 D318 Won't Start

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KansasD7
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This Cat 12 (8T1340😎 grader with D318 was my Dad's and hadn't been started in 4 years. It has a 24V starter (no pony), but someone had stolen the batteries and cables, so I pull started it a few weeks back. Before pulling it I checked all the fluids. It had 5 gals in the diesel tank, so I cracked the drain valve at the bottom of the tank and caught a little fuel to see what was there. No water, but a little sediment.

It pull started with a dozer in probably 20 feet. So far, so good. I came back in a couple of weeks with a semi and lowboy, pull started it again, drove it onto the trailer, and moved it 220 miles to my house in Kansas. I pulled it off the trailer, and then pull started it again before parking it.

Next, I bought two new batteries and installed the batteries and new cables. I also added another 10 gals of diesel to the tank. It took a little bit of ether to start, but the starter spun the engine quickly and it produced a lot of smoke before starting.

After starting it ran well and I was running it and varying the power (and enjoying the sound of that D318 six cylinder) to warm it up before changing the oil. After running a couple of minutes it stopped responding to the throttle, slowed to idle, and finally stopped. The engine was producing good oil pressure.

Thinking a fuel problem, I did the following:
[ol]
  • Removed the fuel line and adapter on the side of the fuel transfer pump. There was a little sediment in the passage in front of the check valve, but the rubber faced check valve seemed to be sealing (sealing surface was not rough) and the spring seemed to be pretty strong. Regardless, I stretched the spring a bit and put everything back together.
  • I removed the fuel line from the transfer pump to the fuel tank and blew it out. I was concerned that adding 10 gals of fuel before starting had stirred up a bunch of sediment in the tank that was causing problems, but the line was clean and very little material blew out of the fuel line. The fuel I added was fresh and clean, pumped from the filtered transfer tank in my truck.
  • I removed the fuel pressure gauge and using a regulated air supply determined that the gauge was working and topped out at about 20 psi.
  • I removed the line running from the air bleed at the top of the filter tower and blew it out to make sure it was not plugged. It was not.
  • I added a little air pressure to the tank, cracked the filter tower air bleed screw, and after a couple minutes a stream of fuel was coming out of the air bleed.
  • Topped off the batteries with charge and spun the engine quite a bit, but no smoke, so the engine was still not getting fuel. BTW, there is no compression release on this engine, so when the pony was removed, this must have also been removed.
  • After reading horror stories on here about filter towers loaded with several inches of sediment, I went to Caterpillar and bought new fuel filters (2A-5886) and two new filter tower gaskets (7B-7635). Foley Cat in Kansas City had plenty. I re-removed the fuel line adapter block/check valve, opened up the drain tube on the bottom of the filter tower (nothing but clean fuel came out), removed the tower top and replaced the 4 filters. As shown in this picture, the old filters looked pretty clean to me, but it never hurts to have new ones.
  • With the filter tower drained and the filters removed, I used a light to inspect the condition of the lower section of the filter tower. To my surprise, there was just a small amount of sediment at the very bottom, but otherwise everything was really clean.
  • After putting everything back together, I opened up the air bleed at the top of the filter tower and added a little air pressure to the fuel tank. After many minutes, clean fuel started flowing out of the bleed line.
  • Next, I closed the throttle (idle position), opened up the bleed screws on the fuel injectors and waited until fuel started coming out.
  • Topped off the batteries and spun the engine again with the throttle cracked a bit. Even though it spun rapidly, no smoke, no fuel pressure (good oil pressure), and no signs of wanting to start.
  • [/ol]

    Not mentioned above, but I also serviced the air filter oil bath and removed all the mud in there after the engine initially quit running.

    Next, I plan to pull the fuel transfer pump since the fuel pressure gauge (and lack of smoke) tell me that it is not working, but this doesn't make a lot of sense to me since the engine was running so nicely before it lost power.

    What am I missing? Any additional ideas?

    Thanks,
    Steve
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    Fri, Dec 2, 2016 8:56 AM
    ccjersey
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    Will it run with the air pressure applied to the fuel tank?

    Any chance the tank valve is nearly closed or plugged? Seems like if your transfer pump was worn out, the air pressure would force fuel through in short order.

    Are you sure you didn't drop the spring or poppet in the bypass valve when reassembling?
    D2-5J's, D6-9U's, D318 and D333 power units, 12E-99E grader, 922B & 944A wheel loaders, D330C generator set, DW20 water tanker and a bunch of Jersey cows to take care of in my spare time😄
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    Fri, Dec 2, 2016 9:20 AM
    BillWalter
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    Reply to ccjersey:
    Will it run with the air pressure applied to the fuel tank?

    Any chance the tank valve is nearly closed or plugged? Seems like if your transfer pump was worn out, the air pressure would force fuel through in short order.

    Are you sure you didn't drop the spring or poppet in the bypass valve when reassembling?
    [quote="ccjersey"]Will it run with the air pressure applied to the fuel tank?

    Any chance the tank valve is nearly closed or plugged? Seems like if your transfer pump was worn out, the air pressure would force fuel through in short order.

    Are you sure you didn't drop the spring or poppet in the bypass valve when reassembling?[/quote]

    You can't be too far away from me if you went into the KC Foley store for parts
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    Fri, Dec 2, 2016 9:43 AM
    KansasD7
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    Reply to ccjersey:
    Will it run with the air pressure applied to the fuel tank?

    Any chance the tank valve is nearly closed or plugged? Seems like if your transfer pump was worn out, the air pressure would force fuel through in short order.

    Are you sure you didn't drop the spring or poppet in the bypass valve when reassembling?


    I haven't tried to start it with air pressure applied to the tank, but good idea. I can easily try that.

    [quote]Are you sure you didn't drop the spring or poppet in the bypass valve when reassembling?[/quote]

    Yes, very sure. I have had this apart twice, and when I pulled it back apart when changing the filters the spring/poppet were properly installed.

    [quote]Any chance the tank valve is nearly closed or plugged? Seems like if your transfer pump was worn out, the air pressure would force fuel through in short order. [/quote]

    When I had the fuel line from the tank to the transfer pump removed I had a chance to make sure that I could identify the fully open/closed position of the valve and I didn't see any signs of valve blockage. As you know, with each 90 degs of stem rotation, the valve either opens or closes.

    Thanks for the ideas,
    Steve
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    Fri, Dec 2, 2016 10:02 AM
    Old Magnet
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    Reply to KansasD7:


    I haven't tried to start it with air pressure applied to the tank, but good idea. I can easily try that.

    [quote]Are you sure you didn't drop the spring or poppet in the bypass valve when reassembling?[/quote]

    Yes, very sure. I have had this apart twice, and when I pulled it back apart when changing the filters the spring/poppet were properly installed.

    [quote]Any chance the tank valve is nearly closed or plugged? Seems like if your transfer pump was worn out, the air pressure would force fuel through in short order. [/quote]

    When I had the fuel line from the tank to the transfer pump removed I had a chance to make sure that I could identify the fully open/closed position of the valve and I didn't see any signs of valve blockage. As you know, with each 90 degs of stem rotation, the valve either opens or closes.

    Thanks for the ideas,
    Steve
    Understood that the gauge works but you don't mention what pressure you have when cranking or running. Fuel pressure needs to be verified. Also would be a good idea to bleed air at the injectors as well as the pump bleed screws and it may take more than one cycle of bleeding to get all the air out.
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    Fri, Dec 2, 2016 11:23 AM
    oldbeek
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    Reply to Old Magnet:
    Understood that the gauge works but you don't mention what pressure you have when cranking or running. Fuel pressure needs to be verified. Also would be a good idea to bleed air at the injectors as well as the pump bleed screws and it may take more than one cycle of bleeding to get all the air out.
    X 2 on cracking injector lines at the injectors. What fuel pressure did it have just before it quite and you were warming it up. To get the regulator and spring out of the picture, recently i made a heavy gasket that covered that hole and just took the regulator and spring out . It did give me a few extra PSI. Put it back together correctly after i got it running.
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    Fri, Dec 2, 2016 12:14 PM
    rmyram
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    when i bled the injection pump on my d318, i started at the front pump closest to the water pump and worked my way to the back to make sure that no air happened to get back in to the pump i just bled.

    Om is right what is fuel pressure when cranking? you can crank it with the engine throttle wide open, have you checked the rack to make sure it didn't get bound in the closed position?
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    Fri, Dec 2, 2016 12:47 PM
    KansasD7
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    Reply to Old Magnet:
    Understood that the gauge works but you don't mention what pressure you have when cranking or running. Fuel pressure needs to be verified. Also would be a good idea to bleed air at the injectors as well as the pump bleed screws and it may take more than one cycle of bleeding to get all the air out.
    Hello OM,



    I have never been down at the engine looking at the fuel pressure when it was running (haven't seen it run much yet unfortunately).

    As it says in step 11 of my post above, there is no indication of fuel pressure now when cranking the engine. I watch the fuel gauge pretty closely during engine cranking now and it is possible the needle is moving up slightly off zero, but not much, if any.

    When I am adding pressure to the tank during purging, I see a slight rise in the fuel pressure on the gauge.

    [quote]Also would be a good idea to bleed air at the injectors as well as the pump bleed screws and it may take more than one cycle of bleeding to get all the air out.[/quote]

    Ok, will try that.

    Thanks for your suggestions,
    Steve
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    Fri, Dec 2, 2016 9:27 PM
    KansasD7
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    Reply to oldbeek:
    X 2 on cracking injector lines at the injectors. What fuel pressure did it have just before it quite and you were warming it up. To get the regulator and spring out of the picture, recently i made a heavy gasket that covered that hole and just took the regulator and spring out . It did give me a few extra PSI. Put it back together correctly after i got it running.


    Hello,

    When it was running I was in the cab and could see oil pressure and water temperature, but not the fuel pressure gauge down on the engine.

    At that point in the project I wasn't concerned about fuel pressure because I had never had a problem starting the engine (pulled it 3 times and started it once with the electric starter). It has only been since the engine died during warm up that there seems to be an absence of fuel pressure, but I have no idea what the fuel pressure gauge was reading prior to that time.

    I was also thinking about closing off the bypass valve hole to remove that variable from the picture, but wasn't sure if that would cause other problems or not.

    Thanks,
    Steve
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    Fri, Dec 2, 2016 9:36 PM
    KansasD7
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    Reply to rmyram:
    when i bled the injection pump on my d318, i started at the front pump closest to the water pump and worked my way to the back to make sure that no air happened to get back in to the pump i just bled.

    Om is right what is fuel pressure when cranking? you can crank it with the engine throttle wide open, have you checked the rack to make sure it didn't get bound in the closed position?
    [quote="rmyram"]when i bled the injection pump on my d318, i started at the front pump closest to the water pump and worked my way to the back to make sure that no air happened to get back in to the pump i just bled.

    Om is right what is fuel pressure when cranking? you can crank it with the engine throttle wide open, have you checked the rack to make sure it didn't get bound in the closed position?[/quote]

    Hello,

    No or slight fuel pressure when cranking.

    I don't know how to check that the rack did not get bound in the closed position, but will try to investigate.

    This is an interesting theory since I was moving the throttle up and down (and smiling like a Cat owner) just before the engine stopped responding to throttle movement.

    Thanks,
    Steve
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    Fri, Dec 2, 2016 9:39 PM
    kracked1
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    Reply to KansasD7:
    [quote="rmyram"]when i bled the injection pump on my d318, i started at the front pump closest to the water pump and worked my way to the back to make sure that no air happened to get back in to the pump i just bled.

    Om is right what is fuel pressure when cranking? you can crank it with the engine throttle wide open, have you checked the rack to make sure it didn't get bound in the closed position?[/quote]

    Hello,

    No or slight fuel pressure when cranking.

    I don't know how to check that the rack did not get bound in the closed position, but will try to investigate.

    This is an interesting theory since I was moving the throttle up and down (and smiling like a Cat owner) just before the engine stopped responding to throttle movement.

    Thanks,
    Steve
    Yank hard on the throttle. Have you tried starting at full throttle? Is the linkage still hooked up to the pump?
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    Fri, Dec 2, 2016 11:04 PM
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