UNIT1L1S Cat Fuel Systems PDF
UNIT1L1S Cat Fuel Systems PDF
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
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
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
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%
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%
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
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.
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
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
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.
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
FUEL SULFUR
Test Specification Fuel Sulfur Content
ASTM D129 Standard Fuel 0.5%
ASTM D2622 Low Sulfur Fuel 0.05%
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
Human Hair
.0035 inch
.0889 mm
.0001 inch
.00254 mm
.0001 inch
.00254 mm
.000039 inch
.001 mm
Sources
of
Contamination
Fig. 1.1.23 Sources
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.
High
Efficiency
Filters
Fig. 1.1.24 Filters
Minimizing
Fuel
Contamination
Fig. 1.1.25 Fuel Contamination
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.