Fuel Treatments in Heavy Equipment and Their Role in Engine Longevity

[MikePhua]

The Rise of Fuel Additives in Diesel Equipment Maintenance
As diesel engines evolved to meet stricter emissions standards and higher performance demands, the role of fuel treatments shifted from optional enhancements to essential maintenance tools. Ultra-low sulfur diesel (ULSD), mandated in many regions since the mid-2000s, lacks the natural lubricity of older diesel formulations. This change, while beneficial for air quality, introduced new challenges for fuel system durability, injector cleanliness, and cold-weather reliability.
Heavy equipment manufacturers such as Caterpillar, Komatsu, and Volvo began recommending fuel additives to counteract these deficiencies. In parallel, the fuel additive industry expanded rapidly, with global sales exceeding $2.5 billion annually by 2023. Products now target specific issues such as microbial contamination, injector fouling, and cetane deficiency.
Types of Fuel Treatments and Their Functions
Fuel additives are categorized based on their primary function. Operators should select treatments based on climate, equipment age, and usage patterns.

• Lubricity Enhancers
  Restore lost lubrication in ULSD, protecting injectors and fuel pumps from premature wear.
  
• Cetane Improvers
  Boost combustion quality by increasing the cetane number, leading to smoother ignition and reduced engine knock.
  
• Detergents and Dispersants
  Clean injectors and prevent deposit formation, maintaining optimal spray patterns and fuel atomization.
  
• Cold Flow Improvers
  Modify wax crystal formation to prevent fuel gelling in low temperatures, essential for winter operation.
  
• Biocides and Water Dispersants
  Eliminate microbial growth and moisture in fuel tanks, preventing sludge formation and corrosion.
  
• Stability Agents
  Prevent oxidation and thermal breakdown of stored diesel, extending shelf life and reducing varnish formation.
  

In one fleet in Alberta, switching to a multi-function additive reduced injector replacements by 40% over two years, especially in machines operating in sub-zero conditions.
Signs That Fuel Treatment Is Needed
Operators should monitor for the following indicators:

• Hard starting or excessive white smoke
  
• Loss of power under load
  
• Increased fuel consumption
  
• Frequent fuel filter clogging
  
• Visible sludge or water in fuel tank
  
• Injector misfire or rough idle
  

In one case from Maine, a grader began stalling during cold mornings. Analysis revealed wax crystal formation in the fuel lines. After adding a cold flow improver and draining the tank, the issue was resolved.
Recommended Products and Performance Data
Several fuel treatments have demonstrated measurable benefits in field trials:

• Hot Shot’s Secret EDT
  Increases cetane by up to 7 points, improves fuel economy by 7.3%, and enhances lubricity by 26%.
  
• Diesel Extreme
  Cleans entire fuel system and boosts combustion efficiency, reducing emissions and regens.
  
• Pittsburgh Power Max Mileage Catalyst
  Improves throttle response, reduces DPF regens, and cleans EGR components.
  
• Stanadyne Performance Formula
  Provides lubricity, cleans injectors, and stabilizes fuel for long-term storage.
  
• Clean Air Fleet Diesel Additive
  Designed for DPF-equipped machines, reduces regeneration cycles and combats corrosion.
  

In one municipal fleet in Texas, using Stanadyne Performance Formula across 30 machines led to a 12% reduction in fuel-related downtime and extended injector life by 1,500 hours.
Application Guidelines and Dosage Strategy
To maximize effectiveness:

• Follow manufacturer dosage instructions precisely
  
• Treat fuel at every fill-up for consistent protection
  
• Use biocides quarterly in humid climates
  
• Add cold flow improvers before temperature drops
  
• Shake or mix additive thoroughly before use
  
• Monitor fuel economy and engine behavior after treatment
  

Recommended dosage ranges:

• Lubricity enhancer: 1 oz per 10 gallons
  
• Cetane booster: 2 oz per 10 gallons
  
• Biocide: 1 oz per 20 gallons (quarterly)
  
• Cold flow improver: 1 oz per 10 gallons (seasonal)
  

In one rebuild in Oregon, a technician added a sight glass to the fuel tank and tracked additive performance visually. He observed reduced water accumulation and cleaner fuel over six months.
Storage and Contamination Prevention
Fuel stored for extended periods is vulnerable to degradation. Additives help mitigate risks, but proper storage practices are equally important.
Best practices:

• Use sealed, vented tanks with water separators
  
• Store fuel below 70°F when possible
  
• Rotate stock every 90 days
  
• Add stabilizers to fuel stored over 30 days
  
• Inspect tanks monthly for microbial growth or sediment
  

In one agricultural operation in France, adding stabilizers and installing tank desiccant breathers reduced fuel spoilage and injector failures during seasonal equipment downtime.
Conclusion
Fuel treatments are no longer optional in modern diesel equipment—they are strategic tools for protecting engines, reducing maintenance costs, and ensuring reliable performance. Whether combating cold starts, microbial contamination, or injector wear, the right additive applied consistently can extend engine life and improve operational efficiency. As fuel chemistry continues to evolve, so too must the strategies used to preserve it.