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UNIT1L1S Cat Fuel Systems PDF

This document provides an overview of a unit on Caterpillar fuel systems. It describes the unit objectives which are to understand fuel characteristics, proper fuel selection based on Caterpillar standards, fuel system maintenance procedures, and how to evaluate calibration fluid in a lab exercise. The first lesson focuses on fuel selection and discusses the attributes of different fuels and how fuel quality can impact engine performance and life. It provides details on Caterpillar's specifications and requirements for preferred distillate fuels and permissible fuels like crude oils and blended fuels.

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0% found this document useful (0 votes)
239 views24 pages

UNIT1L1S Cat Fuel Systems PDF

This document provides an overview of a unit on Caterpillar fuel systems. It describes the unit objectives which are to understand fuel characteristics, proper fuel selection based on Caterpillar standards, fuel system maintenance procedures, and how to evaluate calibration fluid in a lab exercise. The first lesson focuses on fuel selection and discusses the attributes of different fuels and how fuel quality can impact engine performance and life. It provides details on Caterpillar's specifications and requirements for preferred distillate fuels and permissible fuels like crude oils and blended fuels.

Uploaded by

bejoythomas
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
You are on page 1/ 24

Unit 1: Caterpillar Fuel Systems

UNIT 1
Caterpillar Fuel Systems

Unit Introduction:
This unit describes the characteristics, differences, maintenance and
calibration procedures associated with Caterpillar Fuel Systems.

Unit Objectives:
At the completion of this unit each student will be able to: Understand
fuel characteristic differences, select fuels properly based on Caterpillar
standards, understand proper fuel system maintenance procedures, and
properly evaluate the usability of a sample of calibration fluid in a lab
exercise.

Unit Tooling:
None Required

Unit References:
Student Worktext
Diesel Fuel and your Engine SEBD0717
9U7840 Calibration Fluid Test Kit
Engine Data Sheet 60.2 "Fuel Conservation Practices" LEKQ4487
Service Magazine, "New Fuel Heater Prevents
Cold Weather Fuel Problems," October 7, 1985,
Form Number (page 10) SEBD1584
Service Magazine, "Two New Cold Weather Fuel
Heaters Available," November 3, 1986,
Form Number (page 4) SEBD1686
Service Magazine, "Fuel Heaters Are Now Available
As An Attachment For some Machines," August 18, 1980,
Form Number (page 3) SEBD1027
Special Instruction, Form Number SEHS7643
NOTES
Lesson 1: Fuel Selection
Lesson 1: Fuel Selection

FUEL SELECTION

Fig. 1.1.1 Fuel Selection

Lesson Introduction
This lesson discusses the proper fuel selection techniques and
practices necessary for maintaining Caterpillar Fuel Systems.

Reference Materials:
Diesel Fuel and Your Engine SEBD0717
Student Worktext
Engine Data Sheet 62.0 LEKQ3255
Unit 1 1-1-3 Fuel Systems
Lesson 1

Fuel Selection
Fig. 1.1.2 Fuel Selection

This Lesson will discuss the attributes of fuel and how it affects the
performance of a diesel engine. Many people think that all fuel is the
same, and that it does not change engine performance. The inverse is
probably more correct. We will explore some of the differences that
can be found in different fuels.

Cetane Number

Startability and Performance


Fig. 1.1.3 Stability and Performance

Caterpillar wants its customers to get the maximum service life from
their engines with a minimum of downtime. One method to assure
good continuous engine performance is to select the best available
fuel. Fuel quality is critical to engine life and good performance.
Although called diesel fuel, the exact mixture could be slightly
different every fill up. Therefore, with every fill up, the engine may
perform differently.
Unit 1 1-1-4 Fuel Systems
Lesson 1

PREFERRED FUELS
• Diesel Fuel
• Fuel Oil
• Furnace Oil
• Gas Oil
Fig. 1.1.4 Preferred Fuels

Caterpillar engines have the ability to burn a wide range of fuels.


Distillate fuels are the preferred fuels for use in Caterpillar engines.
Those fuels are commonly called diesel fuel (number 1 or 2), fuel oil,
furnace oil, gas oil or kerosene.
Experience has proven that the use of distillate fuels will result in
maximum engine service life, performance and durability. Distillate
fuels usually contain smaller amounts of water, sulfur and sediment
than the second type of fuels, permissible.
Unit 1 1-1-5 Fuel Systems
Lesson 1

PREFERRED FUELS
Requirement Number 2 Low Sulfur
Cetane No. (PC) 35 min. 35 min.
Cetane No. (DI) 40 min. 40 min.
Water and Sediment 0.05% max 0.05% max
API - min. 30 30
API - max. 45 45
Sulfur 0.5% 0.05%

Pour Point: 10°F below ambient temperature


Cloud Point: Not higher than ambient temperature

Fig. 1.1.5 Preferred Fuel

Figure 1.1.5 shows the Caterpillar specifications for preferred fuels. It


is separated into two groups: standard fuel, number 2, and low sulfur
fuel. It should be noted that the only variation between the two
columns is the amount of sulfur contained in the fuel.
Each type (diesel fuel, fuel oil, furnace oil, kerosene) of preferred
fuels can be put into either category depending on sulfur content.
Standard fuel is available for off highway use in heavy equipment,
industrial engines and commercial marine applications in the United
States and Canada. For identity of this fuel, the governments require
a dye to be added.
Low sulfur fuel is required in on highway truck and pleasure craft
marine applications in the United States and Canada. No dye is
added to this fuel. It is almost clear with a slight yellow green tint.
Unit 1 1-1-6 Fuel Systems
Lesson 1

Permissible Fuels
• Crude Oils
• Blended Fuels
Fig. 1.1.6 Permissible Fuels

The use of some crude oils and blended fuels, is permissible in some
Caterpillar engines. These engines require a special fuel system to
tolerate the differences of these fuels.
Crude oil is oil or fuel that is not yet refined, and is basically the
same as it was originally pumped from the ground.
Blended fuel, sometimes called heavy or residual fuel, is composed of
the remaining elements from crude oil after the oil has been refined
into diesel fuel or gasoline. These elements can be combined or
diluted with a lighter fuel so they can flow. At times these fuels have
to be heated or centrifuged to be used.
If crude oil or blended fuels are used, additional service procedures
may be required, and reduced service life may be experienced.
Unit 1 1-1-7 Fuel Systems
Lesson 1

PERMISSIBLE FUELS
Requirement Crude Oils Blended Fuel
Cetane No. (PC) 35 min. 35 min.
Cetane No. (DI) 40 min. 40 min.
Water and Sediment 0.5% max 0.5% max
API - min. 30 30
API - max. 45 45
Sulfur 0.5% 5.0%

Pour Point: 10°F below ambient temperature


Cloud Point: not higher than ambient temperature

Fig. 1.1.7 Permissible Fuels

Figure 1.1.7 shows the Caterpillar specifications for permissible fuels.


Again, it is separated into two groups, crude oil, and blended fuel. It
should be noted that these fuels are allowed higher concentrations of
water and sediment than are the preferred fuels.
Because they can contain higher levels of water, sediment and trace
metals, the owner may need to monitor and evaluate oil change
intervals and use extra filtration to remove solids and/or install fuel
heaters and centrifuges to make the fuel pumpable.
Also note the difference in sulfur content between crude oil and the
blended fuel.

Fig. 1.1.8 Fuel Cleanliness

Although the U.S. and Caterpillar standards for cleanliness of fuel are the
same, that does not mean that all fuels coming from the pump meet these
standards.
Water and sediment can be introduced to the fuel at many locations
between the oil well and the engine’s fuel tank. This introduction can
happen even after the fuel is in the tank. If a vehicle is parked overnight
with a low fuel level, the water in the air trapped at the top of the fuel tank
condenses into water droplets which then fall into the fuel.
Unit 1 1-1-8 Fuel Systems
Lesson 1

Fig. 1.1.9 Contaminants

Crude oil, blended fuel and even distilled fuels may contain excessive
amounts of water and/or sediment which require pre-treatment before
delivery to the fuel injection system. Some of these contaminants can
be removed by using a settling tank. Fuel storage tanks should be
constructed on an angle so water and sediment will settle in the low
end. Contaminants can then be drained off periodically. Care must
be taken when disposing of the material drained off, since it is
considered hazardous waste in some areas. Water in the fuel storage
tanks can also lead to the growth of bacteria. These bacteria can plug
fuel filters, causing low power in engines. Storage tanks should be
checked for bacterial growth. There are fuel and water soluble
additives which can be added to storage tanks to control bacteria.

Fig. 1.1.10 Water Separator

Water which remains in the fuel can be taken out by a water separator
in most cases. In severe applications, a large capacity water separator
can be used. A water separator is only as good as its maintenance.
The water must be drained off before the rated water capacity of the
unit is reached. Once the water holding capacity of the separator is
reached, all additional water will pass through the separator.
Unit 1 1-1-9 Fuel Systems
Lesson 1

Cetane Number

Startability and Performance


Fig. 1.1.11 Cetane Number

Cetane is a chemical found naturally in fuel. The Cetane number (the


amount of the cetane present in the fuel) is a measurement of the
ignition quality of a fuel. Engine startability and acceleration under
load are especially sensitive to the fuel cetane rating. A higher cetane
rating assures ease of starting in most conditions. Fuels must have a
minimum cetane number of 35 for precombustion chamber engines
and 40 for direct injection engines. Fuel with cetane levels lower
than minimum can cause hard starting, white smoke at start-up and
poor engine performance.
An increase in the cetane number will lower the temperature at which the
engine can be started.
Unit 1 1-1-10 Fuel Systems
Lesson 1

Fig. 1.1.12 Cloud Point

At low temperatures, any fuel may contain solid particles of wax


which could plug the filters rapidly. The cloud point of fuel is the
temperature at which some of the heavier paraffin components (wax)
start to form crystals. This is a natural process as the temperature is
causing the fuel to begin its change from liquid to solid. These wax
crystals give the fuel a cloudy appearance. This wax is not a
contaminant, but is an important element of diesel fuel and has a high
energy content and a very high cetane value. The cloud point of the
fuel is important because wax can plug the fuel filter.
If the cloud point of the fuel is lower than the lowest ambient
temperature at which the engine will be expected to start and operate,
filter plugging will not be a problem.
Unit 1 1-1-11 Fuel Systems
Lesson 1

Fig. 1.1.13 Pour Point

The pour point of a fuel is an indication of the minimum temperature


at which the fuel will flow. At the pour point temperature, the
amount of wax crystals increases to a point where they connect
together. This can restrict the flow of fuel from the tank to the engine
transfer pump, but if the fuel stays around the fuel pick up tube, the
transfer pump will move it. The pour point is approximately
6°C (10ºF) below the cloud point.
The pour point can be improved with flow improvers or the addition
of kerosene or a lighter diesel. Fuel heaters cannot normally solve
problems related to a high pour point temperature since they normally
use engine coolant as their heat source.
Unit 1 1-1-12 Fuel Systems
Lesson 1

Fig. 1.1.14 Fuel Heater

A fuel heater will keep the wax dissolved and permit it to flow
through the filters with the fuel. Several types of fuel heaters are
available on Caterpillar engines as factory installed options. They
can be installed between the fuel filter base and the spin-on filter or
between the fuel tank and fuel filter. Most of the heaters use engine
coolant to heat the fuel and prevent ice or wax crystal formation in
the filter. Fuel heaters should only be used as required, because as
fuel temperature rises, engine performance declines. There is
approximately a 1% horsepower loss for every 6ºC (10ºF) increase in
fuel temperature. Fuel heaters should not be used if the ambient
temperature is above 15ºC (60°F), and the fuel temperature at the
outlet of the fuel heater should not be higher than 74ºC (165ºF).
Some electronic engines will adjust fuel rate depending on fuel
temperature. Fuel heaters used on electronic engines should be
thermostatically controlled.
Unit 1 1-1-13 Fuel Systems
Lesson 1

Fig. 1.1.15 Safety Practices

To lower cloud point and pour point temperatures of their fuels, some
users blend diesel fuel with gasoline or naphtha. Because of the
safety hazard involved, Caterpillar does not recommend that users
mix diesel fuel with gasoline or naphtha. Safety practices which may
have worked well with pure diesel fuel will not be adequate when
dealing with these blends. In a fuel tank, the vapor in the air space
above pure diesel fuel is too lean to be a hazard at normal ambient
temperatures. Pure gasoline vapors are too rich. However, when
diesel fuel is mixed with gasoline or naphtha, the vapor-to-air ratios
can be explosive. Caterpillar recommends the other methods already
discussed to lower pour point or cloud point temperatures.

Fig. 1.1.16 Pour and Cloud Point Adjustment

Some users also like to use alcohol to adjust pour and/or cloud point.
Alcohol, either methanol or ethanol, has a low cetane number and
poor lubricating characteristics. The cetane numbers of ethanol and
methanol are similar—in a range of 0 to 10. This means that pure
alcohol does not have good ignition characteristics when used in a
diesel engine and must be mixed with large quantities of cetane
improvement additives which are quite expensive. Also, in current
fuel injection systems, the diesel fuel lubricates some of the fuel
injection system components. Alcohol does not have good
lubrication characteristics.
Unit 1 1-1-14 Fuel Systems
Lesson 1

Fig. 1.1.17 Sulfur Content

Caterpillar Diesel engines have a “silent” enemy within diesel fuel -


sulfur. It is called the “silent” enemy because sulfur content does not
directly affect engine performance. It has no effect on engine
startability or power. Sulfur content doesn’t become a harmful factor
until after the fuel has been burned. During the combustion process,
sulfur dioxide (SO2) and sulfur trioxide (SO3) are formed. These
oxides of sulfur combine with the water vapor formed during
combustion to create sulfuric acid. This acid causes corrosive wear in
engines and increases the chance of early engine failure.

FUEL SULFUR
Test Specification Fuel Sulfur Content
ASTM D129 Standard Fuel 0.5%
ASTM D2622 Low Sulfur Fuel 0.05%

Fig. 1.1.18 Fuel Sulfur

In the United States, fuels which meet ASTM 1-D and 2-D
specifications must contain no more than 0.5% sulfur by weight.
Fuels that meet ASTM 1-D and 2-D for low sulfur must contain no
more than 0.05% sulfur by weight.
This does not mean that every fuel will meet this specification. In
fact, fuels with sulfur content in excess of 0.5% have regularly been
found in field surveys.
Caterpillar engines can burn these higher sulfur fuels. However, to
use fuels with sulfur content greater than 0.5%, extra precautions
must be taken to protect the engine from corrosive wear.
Unit 1 1-1-15 Fuel Systems
Lesson 1

WHEN YOU BUY FUEL


• Meet Caterpillar specifications
• Keep it clean
Fig. 1.1.19 Fuel Selection

Clean fuel meeting Caterpillar’s fuel recommendations promotes


maximum engine service life and performance. Anything less is a
compromise and the risk is the user’s responsibility. Dirty fuels and
fuels not meeting Caterpillar’s minimum fuel specifications will
adversely affect engine performance and will shorten engine life. It is
good economics to carefully consider fuel selection.

Fuel Contamination Control

Fig. 1.1.20 Fuel System Components

Dirty Fuel is Your Engine's Worst Enemy


This unseen villain can rob the engine of power, accelerate wear of
sensitive fuel system components and reduce fuel efficiency.
Keeping the fuel and the fuel system clean should be top priority,
especially in construction, mining, and other dusty applications where
higher horsepower engines are in use. With the higher injection
pressures and closer tolerances of today's diesel engines, clean fuel
delivers maximum performance, productivity and service life.

One critical element in any fuel contamination control program is Cat


High Efficiency Fuel Filters. They're specially designed for today's
diesels, using a super-fine filtration media for maximum filtration.
Unit 1 1-1-16 Fuel Systems
Lesson 1

Why clean fuel is so important


Fuel contamination is, and always has been, a concern with all types
of Cat diesel engines. It has become even more important in recent
years as engineers have worked to make diesel engines more
economical and environmentally friendly. As emissions and fuel
consumption have decreased, injection pressures and tolerances
between components have increased. Higher RPMs submit precision
components to even more potential wear and abrasion.
Today's Cat engines deliver more horsepower, better response and
better fuel economy than ever. They are also more susceptible to
wear and damage from fuel system contaminants. Damage can be
caused by anything in the fuel system that should not be there,
including particles, heat, water and air bubbles. Together or alone
these contaminants can drain power from the engine, accelerate
component wear and eventually lead to a breakdown.

Fig. 1.1.21 Contamination

As little as one spoonful of dirt in a tank of fuel can ruin a fuel


injector in less than eight hours.
Unit 1 1-1-17 Fuel Systems
Lesson 1

How Big is a Micron?


(2,000 Times Size)

Human Hair
.0035 inch
.0889 mm

.0001 inch
.00254 mm

.0001 inch
.00254 mm
.000039 inch
.001 mm

Fig. 1.1.22 Micron

Out of sight is not out of mind


The most controllable contaminants are abrasive particulates, which
can vary greatly in size, hardness and abrasion. The comparison
illustrated here demonstrates the very tight clearances in the fuel
system and the size of the visible particles. As can be seen, even
particles that aren't visible can wear away at the fuel system and
reduce performance.

Sources
of
Contamination
Fig. 1.1.23 Sources

Sources of Fuel Contamination


In the Fuel
A reliable fuel supplier is the best defense against source
contamination. Demand periodic sampling and testing to assure the
consistent quality needed for top performance.
Unit 1 1-1-18 Fuel Systems
Lesson 1

During Operation
In dusty applications such as construction and mining, airborne
contaminants can be drawn into the fuel tank through the vent tube.
Likewise, a vent in the fuel tank cap can ingest dust if it is not
properly sealed. Contaminants can also develop during storage or
enter the system through improper fuel transfer.
During Service
Any time the fuel system is open, whether it is to change filters,
make repairs or for refueling, contaminants can enter the system.

Where contaminants do their damage


Abrasive contaminants accelerate wear as they move through the fuel
system at very high velocities. In some cases, the contaminants in
the fuel may be as abrasive as the materials used to machine parts in
manufacturing.
Contamination can cause problems throughout the fuel system, but
there are two areas that are especially susceptible to wear and
damage.
Injector Plunger and Barrel
Minimum clearances of 2.5 microns make it critical to maintain a
fluid film between these rapidly moving parts. Microscopic abrasive
particles cause scratching, which can eventually lead to scuffing,
metal-to-metal contact and injector seizure.
Control Valves
Located throughout the fuel system, these valves control fuel
pressure. Contaminants can erode the mating parts of the valves,
causing them to leak and perform below specifications. A loss of
engine power is the result.
Unit 1 1-1-19 Fuel Systems
Lesson 1

High
Efficiency
Filters
Fig. 1.1.24 Filters

Get Maximum Protection with Cat High Efficiency Fuel Filters


Cat High Efficiency Fuel Filters are specially designed for the higher
injection pressures and precision components of today's engines.
They use an exclusively designed filtration media to remove more
than 98 percent of particles 2 microns and larger. More contaminants
are removed, maximizing protection of injectors, pumps and other
fuel system components.
From top to bottom, Cat High Efficiency Fuel Filters are engineered
for performance. Features like spiral roving and acrylic beads
maintain pleat stability and spacing for maximum efficiency and
capacity. The non-metallic center tube is stronger and prevents metal
contamination. The self-lubricating, free-rotating seal prevents
bunching and eliminates leaks.
Talk to a Cat dealer about the benefits of High Efficiency Fuel
Filters.
Unit 1 1-1-20 Fuel Systems
Lesson 1

Minimizing
Fuel
Contamination
Fig. 1.1.25 Fuel Contamination

How to Minimize Fuel System Contamination


During Storage and Transfer
Without proper storage and handling procedures, even the cleanest
fuel can deteriorate or become contaminated. Here are steps which
can be taken to keep sediment, dirt and environmental contaminants
out of the fuel system
- Periodically drain and flush all fuel storage containers, including
tanker trucks and stationary tanks. This will remove sediments that
can easily enter the fuel stream.
- Keep all fuel nozzles, hoses and other equipment clean.
- If a nozzle is dirty, clean it thoroughly before fueling.
- Maintain all hoses, gaskets and seals in fuel storage and transfer
equipment.
- Use line filters on all fuel transfer equipment.
- Never transfer fuel with buckets, funnels or other open containers.
- Only purchase fuel from a reliable, reputable source. To ensure a
consistently high-quality product, demand periodic testing.
Unit 1 1-1-21 Fuel Systems
Lesson 1

During Operation
Fighting fuel contamination is a full-time concern for everyone from
the machine operator to maintenance technicians. This checklist
should be a part of any daily inspection program.
- Repair any fuel line leaks immediately. If fuel is leaking out,
contaminants can also get in.
- Never operate a machine without the properly installed fuel cap.
- If a fuel cap does not seal properly due to deteriorated gaskets or
other damage, replace it immediately.
- Make sure fuel tank vent tubes are open and functioning properly.
- Do not run machines to the point when the fuel tank is completely
empty. Doing so can draw sediment from the bottom of the tank
into the fuel system.
- Alert maintenance and service technicians immediately of any
unexplained power loss, excessive smoke or hard starting,
especially when the engine is warm.

When changing filters


- Maximize filtration protection with Cat High Efficiency Fuel
Filters. The moderate cost difference is made up in greater
protection
- Follow the recommended filter change schedule. If premature filter
plugging occurs, consider the fuel quality and other contamination
sources.
- Remove filters carefully, making sure not to knock dirt and debris
from the engine compartment into openings.
- Keep filters packed in their original box until they are installed.
- Never pre-fill a new filter--doing so allows some fuel to bypass the
filter altogether.
.
Unit 1 1-1-22 Fuel Systems
Lesson 1

When performing Engine Service


- Clean dirt, dust and other debris from the engine compartment
before removing filters and other fuel system components.
- Use a high pressure wash to blast mud, dust and dirt and other
built-up grime off the engine before "opening" the engine for
repairs.
- Tightly cap or plug all openings during repairs, even if they are
needed only for a few minutes.
- Clean reusable parts with solvent using proper cleaning and drying
methods.
- Never place components directly on the ground.
- Keep new parts in their original package until needed.
- Don't reuse seals, replace them.
- Perform routine inspection of fuel line connections from the tanks
to the fuel pump.
- Maintain a regular schedule for draining machine fuel tanks:
weekly for severely dusty conditions, every three months for
normal conditions.
NOTES

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