Return fuel melting fuel tank???

I would try to test the temp of the fuel going to and from the cp3. Should be able to run a short line from the return to a 5 gallon bucket then stick a temp gauge in it imediately to see what it says.

I would also worry if its melting a plastic fuel tank what else is it causing damage to, maybe the inside of the cp3, injectors? Are you overdriving the cp3 in some way?
 
Oh man........:hehe: Yur so funny.
I think I understand the concept of the fuel filter trapping media and all that stuff.... I asked what is the media trapped in said filter?
Did you know Dan, that it is possible to dissect said filtering device and investigate the contents? Or don't they do that in Mizzzora?LOL

Is it actually melted plastic?
Cuz when plastic cools it becomes a solid again.
 
Snedge said:
Oh man........:hehe: Yur so funny.
I think I understand the concept of the fuel filter trapping media and all that stuff.... I asked what is the media trapped in said filter?
Did you know Dan, that it is possible to dissect said filtering device and investigate the contents? Or don't they do that in Mizzzora?LOL

Is it actually melted plastic?
Cuz when plastic cools it becomes a solid again.
Click to expand...

I know you know Jeff. Just the way you worded it left it open for fun. I think melted plastic is still melted plastic though.

Dissect? What is that? We just bury them out here.
 
I'm not sure what plastic the OEM fuel tanks are molded in, but most plastics don't have a high service temperature - many of them top out ~ 180*F, where creep deformation becomes a mechanical problem before actual meltage.

Bosch engineering references CP3 return fuel max temps of 250*F, so a potential problem could certainly exist. Doubtless one of the reasons for the DuraMax's fan-assisted heat exchanger in front of the tank? The Dodges have bare stainless steel fuel lines between the tank and the engine to provide a measure of passive fuel cooling.

The CP3's integral internal gerotor lift pump generates 180psi in stock trim for the common rail, so fuel heating is unquestionable.

We fabricated a passive fuel cooler under the driver's door on the LazarSmith Special just to address this temperature issue.
 
I have worked on a couple of the local farmers dump trucks and equipment that had filters plugged solid with a brownish rusty colored that was rubbery and kinda plastic like because you could roll it around in your hand and it wouldnt break up. Turns out it is the animal fat that FS is adding to there diesel. We give some of the filters to the FS fuel man and he was taking them to get tested. I have not heard back yet the results. He said that that fuel has a storage life of about 3 months before it grow algea or whatever it is doing.
 
XLR8R said:
I'm not sure what plastic the OEM fuel tanks are molded in, but most plastics don't have a high service temperature - many of them top out ~ 180*F, where creep deformation becomes a mechanical problem before actual meltage.

Bosch engineering references CP3 return fuel max temps of 250*F, so a potential problem could certainly exist. Doubtless one of the reasons for the DuraMax's fan-assisted heat exchanger in front of the tank? The Dodges have bare stainless steel fuel lines between the tank and the engine to provide a measure of passive fuel cooling.

The CP3's integral internal gerotor lift pump generates 180psi in stock trim for the common rail, so fuel heating is unquestionable.

We fabricated a passive fuel cooler under the driver's door on the LazarSmith Special just to address this temperature issue.
Click to expand...

No fan. Just a heat exchanger.
 
Yes, but for the inside of a plastic fuel tank to melt and for pieces of the inside of the tank to become dislodged?? Really?? I think that diesel fuel would have to be somewhere around it's flash point to even attempt to do anything like that. I'm lost. His fuel must be magic.. LOL
 
Hopefully I will get to pull everything apart this week, and I will take pictures.

These are the facts as of right now:

The truck quit running
Cp3s to hot to touch
FASS to hot to touch and straining to run
fuel tank was warm and flexable to the touch
the fuel was not old and the tank was a brand new tank from the dealer and has been in the truck less than 3000miles
 
I will be interested to know hat happened, you have to have something seriously wrong to cause this.
 
I would take a hard look at the FASS. I have seen electric pumps go bad slowly and get untouchablein 2-3 minutes.
 
Wouldnt you think that if the fuel in the tank is that hot where it will soften the plastic that the tank is made of, that the weight of the fuel inside would start pushing the bottom out of the tank? I would put my money on its something else... just not sure what it would be.

Keep us posted.. :Cheer:
 
full pull said:
the tank was a brand new tank from the dealer and has been in the truck less than 3000miles
Click to expand...

Was it doing this before the tank swap?

If the answer is no, I would be suspecting that your problem may go away after a while. You might be collecting the plastic particles left behind after manufacturing the tank. I used to work for a company who built fire trucks and nearly every brand new chassis we received from our parent company (about 750 miles away) had to stop to replace the fuel filter at least once during that trip. After the initial debris was removed from the system they were fine.

toolmanoffroad said:
Wouldnt you think that if the fuel in the tank is that hot where it will soften the plastic that the tank is made of, that the weight of the fuel inside would start pushing the bottom out of the tank? I would put my money on its something else... just not sure what it would be.
Click to expand...

That was my thoughts as well.
 
full pull said:
Hopefully I will get to pull everything apart this week, and I will take pictures.

These are the facts as of right now:

The truck quit running
Cp3s to hot to touch
FASS to hot to touch and straining to run
fuel tank was warm and flexable to the touch
the fuel was not old and the tank was a brand new tank from the dealer and has been in the truck less than 3000miles
Click to expand...

Will the truck even start? You pulled your filler cap off and tried running it?
 
Is it possible the fass is dead and causing problems? Maybe its coming apart or something, and starving the CP3's of fuel at the same time?

Eric
 
This is the second tank same thing happend to the first one, but at that time we didnt know that the fuel was getting hot..


Update:

Fuel filters are packed with plastic pieces..
FASS pump still works new filters and a pick up tube in a 5gal can of fuel the truck started up and ran just fine.


These tanks are made of two types of plastic the outside is black but the inside is white, the white is the only plastic that melted.
 
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this is what the white plastic is like once it gets hot, it doesnt get hard after it cools its kind of soft and spongy and you can scrape it off with your finger nail. this is why it would get sucked up in the filter.
 
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