Installation of the Fuel Consumption Monitoring System for All Commercial Diesel Engines {1250, 1400, 1900, 7490} Caterpillar

Installation of the Fuel Consumption Monitoring System for All Commercial Diesel Engines {1250, 1400, 1900, 7490}

Usage:

Engine Commercial: All Diesel

Introduction

This Special Instruction contains information for installing and configuring the Fuel Consumption Monitoring System on all Caterpillar and non-Caterpillar diesel engines. The Fuel Consumption Monitoring System will measure the net volume of fuel used by an engine. There are three available arrangements:

single transducer up to 30 L/min (7.9 US gpm)
dual transducer up to 30 L/min (7.9 US gpm)
dual transducer up to 100 L/min (26.4 US gpm)

The Fuel Consumption Monitoring System can accommodate engines with supply and return fuel lines, or a supply line only. The Fuel Consumption Monitoring System will transmit the collected data to the main data link to be received by a recording and reporting ECM, such as Cat^® Product Link. This data will then be sent to the back office. Refer to Section "Fuel Transducer Accuracy" for information on system accuracy.

Note: For the single transducer system, disregard any instructions regarding a return transducer. Additional information will be noted as necessary in the following sections of this document.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Personal injury or death can result from improper assembly procedures.

Do not attempt any assembly until you have read and understand the assembly instructions.

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Accidental engine starting can cause injury or death to personnel working on the equipment.
To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.
Turn the battery disconnect switch to the OFF position and lockout the battery disconnect switch with a safety lock.

Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the start switch and battery disconnect location to inform personnel that the machine is being worked on.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

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Be sure all personnel are clear of the equipment while the equipment is being lowered.

Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.
Welding can cause fumes, burn skin and produce ultraviolet rays.
Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.
Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.
Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.
See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.
American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor.
U.S. Department of Labor
Washington, D.C. 20210

Required Parts

Supplied Parts for Installation

Single Transducer Low Flow Rate Fuel Consumption Monitoring System

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Table 1
Contents of the 458-8325 Electrical Installation Gp
Quantity	Part Number	Part Name
100	3S-2093	Cable Straps
6	3T-0852	Locknuts
8	6I-1418	Spacers
6	6V-5221	Bolts
8	8T-9655	Isolation Mounts
6	9N-0869	Hard Washers
1	434-5030	Flow Meter Gp
1	448-8685	Wiring Harness
1	451-4745	Wiring Harness
1	457-3252	Electronic Control Gp
1	473-7726	Film

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Table 2
Optional Extension Harnesses
Part Number	Part Name	Usage
448-8687	Wiring Harness	3.048 m (10 ft) Extension Harness
448-8688	Wiring Harness	6.096 m (20 ft) Extension Harness

Dual Transducer Low Fuel Rate Fuel Consumption Monitoring System

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Table 3
Contents of the 442-2377 Electrical Installation Gp
Quantity	Part Number	Part Name
100	3S-2093	Cable Straps
8	3T-0852	Locknuts
8	6I-1418	Spacers
8	6V-5221	Bolts
8	8T-9655	Isolation Mounts
8	9N-0869	Hard Washers
2	434-5030	Flow Meter Gp ⁽¹⁾
1	448-8685	Wiring Harness
1	448-8686	Wiring Harness
1	451-4745	Wiring Harness
1	457-3252	Electronic Control Gp
1	473-7725	Film

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⁽¹⁾	The supply and return flow meters share part numbers. Each will be clearly marked with an "S" for supply and an "R" for return. During installation be aware of the transducer being installed and the transducer location.

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Table 4
Optional Extension Harnesses
Part Number	Part Name	Usage
448-8687	Wiring Harness	3.048 m (10 ft) Extension Harness
448-8688	Wiring Harness	6.096 m (20 ft) Extension Harness

Dual Transducer High Fuel Rate Fuel Consumption Monitoring System

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Table 5
Contents of the 464-9661 Machine Installation Ar
Quantity	Part Number	Part Name
100	3S-2093	Cable Straps
8	3T-0852	Locknuts
8	6I-1418	Spacers
8	6V-5221	Bolts
8	6V-5223	Bolts
16	7X-0579	Hard Washers
8	8T-9655	Isolation Mounts
4	9N-0869	Hard Washers⁽¹⁾
2	434-5040	Flow Meter Gp
1	464-9812	Film
1	469-0227	Field Installation Gp
1	451-4745	Wiring Harness
1	469-0140	Wiring Harness
1	469-0141	Wiring Harness

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⁽¹⁾	The supply and return flow meters share part numbers. Each will be clearly marked with an "S" for supply and an "R" for return. During installation be aware of the transducer being installed and the transducer location.

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Table 6
Optional Extension Harnesses
Part Number	Part Name	Usage
448-8687	Wiring Harness	3.048 m (10 ft) Extension Harness
448-8688	Wiring Harness	6.096 m (20 ft) Extension Harness

Additional Parts Needed for Installation

Flow Transducer Mounting Bracket

A mounting bracket must be fabricated to support each flow transducer. Since the kit can be used on a large range of engines in both stationary and machine applications, no universal mounting bracket design is possible. A bracket must be field fabricated to allow mounting of the transducers to either the engine or a structural component of the machine. Leave room above the transducer for electrical connections and room at each end for fuel line connections.

Transducers can be mounted one over the other with room left for electrical connections on the bottom transducer. The transducers can also be stacked together by using longer bolts than are provided in the kit. Transducers can be located apart from each other if installation would be easier as each transducer has an independent harness to connect to the ECM.

Fuel Line Fittings and Adapters

Due to the large range of engines that this system may be used on, a list of all fuel line fittings, sizes, styles, and adapters are not possible. As a starting point, the inlet and outlet of each flow transducer is a #12 STOR, female thread. This must be adapted to the correct size fuel line tubing required for each engine. It is likely that the supply and return fuel lines will be of different sizes.

It is recommended that the fuel line tubing be new and in good condition. The tubing must be clean inside. Any small particles that are carried from the inlet hose through the transducer will clog the transducer. In that event, the transducer will need to be removed from the system to dislodge the particles. If hoses are equipped with O-ring fittings, the O-Rings must be new.

Electronic Control Module Mounting Bracket

Given the wide range of machines on which the Fuel Volume Measurement system can be fitted, a standardized mounting method is not possible. A mounting bracket must be fabricated to support the ECM. Refer to Section "Installation of the Electronic Control Module" for ECM mounting requirements.

Fuel Consumption Monitoring System Overview

Applicability

The Fuel Consumption Monitoring System is offered as an aftermarket attachment for use on all diesel fueled off- highway engines, both Caterpillar and competitive brands. The Fuel Consumption Monitoring System provides a fleet solution for precise fuel consumption monitoring.

Fuel Transducer Selection

Before ordering Fuel Flow Transducers for installation, determine the proper size transducer.

If the system has a transfer pump with a flow rate of less than 30 L/min (7.9 US gpm), select the 30 L (7.9 US gal) kit. 30 L (7.9 US gal) kit supports both single and dual fuel line systems.
If the system has a transfer pump with a flow rate of 25 L/min (6.6 US gpm) to 100 L/min (26.4 US gpm), select the 100 L (26.4 US gal) kit. 100 L (26.4 US gal) kit does not support single fuel line systems.

Fuel Transducer Accuracy

Dual Transducer Accuracy

The accuracy of the dual transducer system is determined by the percentage of the supplied fuel spent.

Example: If the fuel transfer pump has a capacity of 3 L/min (0.8 US gpm), the engine would need to consume 0.15 L/min (0.040 US gpm) to achieve 2% accuracy in fuel consumption reporting. This is equal to 5% of the fuel supplied to the engine by the fuel transfer pump. A burn rate of less than 5% of the supplied fuel will result in inaccurate fuel consumption reporting by the system. If your engine achieves burn rates above 12% of the supplied fuel, the accuracy of the system will increase to greater than 1%.

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Table 7
Fuel Spent
Pump Capacity	Accuracy
Pump Capacity	>2%	2%	1%
3 L/min (0.8 US gpm)	0.15 L/min (0.040 US gpm)	0.15 L/min (0.040 US gpm)	0.36 L/min (0.095 US gpm)
6 L/min (1.6 US gpm)	0.3 L/min (0.08 US gpm)	0.3 L/min (0.08 US gpm)	0.72 L/min (0.190 US gpm)
9 L/min (2.4 US gpm)	0.45 L/min (0.119 US gpm)	0.45 L/min (0.119 US gpm)	1.08 L/min (0.285 US gpm)

Single Transducer Accuracy

The single transducer system will report an accuracy of 2% at all burn rates.

Electrical Requirements

This control is designed to operate on 12V DC or 24V DC, negative ground. Current draw of the control package is less than 2.0 amps. Connection of a Cat^® Electronic Technician (Cat ET) communications adapter will add to the current draw.

Remote Monitoring Requirements

Remote monitoring requires that a telematics system such as Product Link be installed on the machine or equipment to transmit the data off-board. The Fuel Consumption Monitoring System kits do not include any required hardware to install a data monitoring and recording device.

Features

The transducers are independently calibrated from the factory with their own K factors. Each system has been pre-programmed with all required calibration data. The only time new K factors require programming is during a service replacement of a transducer or loss of originally programmed calibration values in the ECM.

A new kit will come with these configuration parameters already programmed in the ECM. If a transducer ever requires replacement, the calibration values for the new transducer must be programmed into the existing ECM using Cat ET.

The Fuel Consumption Monitoring System supports transmission of accumulated data over both J1939 and Cat Data Link protocols. The system will respond to monitoring and recording ECMs such as Product Link.

When connected, Cat ET will display current flow rates, supply fuel temperatures, return fuel temperatures, total fuel used, total idle fuel used, and total idle fuel used time.

Installation of Cat^® Product Link or VIMS

To collect fuel usage data using the installed Fuel Consumption Monitoring kit, there must be a data monitoring and recording device such as Cat^® Product Link or VIMS on the machine or equipment. Refer to the Section "Connecting the Fuel Consumption Monitoring System to a Network" of this Special Instruction. The Fuel Consumption Monitoring Kit does not include any required installation instructions or hardware to mount a data monitoring and recording device.

Fuel Consumption Monitoring System Installation

Machine / Engine Preparation

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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine.
To prevent personal injury or death, perform the following:
Park the machine on a smooth level surface.
Lower the blade and or attachments to the ground.
Stop the engine and engage the parking brake.
Block the wheels and install the steering frame lock.
Turn the battery disconnect switch to the OFF position and remove the key.

Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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Be sure all personnel are clear of the equipment while the equipment is being lowered.

Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.

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Structural damage, an overturn, modification, alteration, or improper repair can impair this structure's protection capability thereby voiding this certification. Do not weld on or drill holes in the structure. Consult a Caterpillar dealer to determine this structure's limitations without voiding its certification.

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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

In addition to the normal safety precautions that are taken in the day to day maintenance of heavy machinery, the following preliminary steps are recommended:

Move the machine to a smooth, level location, and away from other working machines and personnel.
Lower the implements to the ground.
Install the frame lock link if applicable into the LOCKED position.
Stop the engine.
Engage the parking brake for the machine.
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Illustration 1 g00104545
Place the battery disconnect switch in the OFF position. Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before servicing the equipment. These warning tags (Special Instruction, SEHS7332) are available from the Caterpillar dealer.
Implement any additional safe job procedures from the work site before continuing with this installation.

Transducer Installation

When selecting a mounting location, consider accessibility to fuel line connections to both the transducers and the engine. Fuel lines should avoid sharp bends, sharp edges, and the exhaust manifold. Leave space between the transducers and the engine to allow for engine movement. Fuel lines must be secured to support their weight and to dampen vibration. Electrical connections should avoid sharp bends at connectors, sharp edges, and chafing surfaces. Harnesses should be supported at no more than 30.48 cm (12 inch) intervals.

Cleanliness of the fuel line components is critical. Shavings and chips from cutting fuel lines must be cleaned out of the fuel lines prior to assembly. The transducers are precision machined to tight tolerances and the smallest solid objects may jam a transducer causing it to become inoperable. Do not remove the plugs from the ends of the transducers until final connections are made. Be careful not to get dust or grease in any of the fuel line components.

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Table 8
30L Transducer Mounting Hardware
Quantity	Part Number	Description
4	6V-5221	Bolts
4	9N-0869	Hard Washers
4	3T-0852	Locknuts

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Table 9
100L Transducer Mounting Hardware
Quantity	Part Number	Description
8	6V-5221	Bolts
16	9N-0869	Hard Washers
8	3T-0852	Locknuts

Supply Transducer Installation

The supply transducer must be mounted on a field bracket and installed in the supply fuel line after the primary filter but before the secondary filter. In systems with only one filter, the transducer must be installed after the filter. Failure to install in the correct location can cause the transducer to behave erratically or become inoperable. Make sure that the transducer is installed in the correct direction of fuel flow.

Use the parts in Table 8 or Table 9 for fastening the supply transducer to the field fabricated mounting bracket.

Once the supply transducer has been mounted, make the supply fuel line connections. The output of the primary fuel filter should feed the inlet of the supply transducer. The output of the supply transducer would then connect to the secondary fuel filter, if present, otherwise the outlet of the supply transducer will connect to the engine. Use 1E0279 tightening specification when installing the fuel line connectors.

Return Transducer Installation

Note: Disregard this section if installing a single transducer system.

The return transducer must be on a field fabricated bracket in a location of the installers choice. When selecting a mounting location, consider accessibility of both fuel line connections to the transducer and the engine. Fuel lines should avoid sharp bends, sharp edges, and the exhaust manifold. Leave space between the transducers and the engine to allow for engine movement. Fuel lines must be secured to support their weight and to dampen vibration. Electrical connections should avoid sharp bends at connectors, sharp edges, and chafing surfaces. Harnesses should be supported at no less than 30.48 cm (12 inch) intervals.

The return transducer must be mounted in the return fuel line prior to the fuel tank. Be sure that the transducer is installed in the correct direction of fuel flow.

Once the return transducer has been installed, make the return fuel line connections. The inlet of the return transducer should be fed from the output of the engine. The output of the return transducer would then connect to the fuel line that returns to the fuel tank. Use 1E0279 tightening specification when installing the fuel line connectors.

Installation of the Electronic Control Module

A field fabricated support bracket must be used to mount the ECM in the system. Some considerations to be made when selecting an ECM mounting location include:

Installation within 121.92 cm (48 inch) of the transducers will require only the base transducer harnesses. More extension harnesses are available to allow installation distances up to 9.144 m (30 ft).
Access to a fused source of 24V power.
Access to key switched power as supplied by the ignition system.
Access to battery ground.
Access to the main data link or links on the machine.

Note: Mounting the ECM on the engine is not recommended due to excessive vibration.

The following parts are included in the kit for fastening the electronic control module to the field fabricated mounting bracket.

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Table 10
Electronic Control Module Mounting Hardware
Quantity	Part Number	Description
4	6V-5221	Bolts
4	3T-0852	Locknuts
8	9N-0869	Hard Washers
4	8T-9658	Spacers
8	8T-9655	Isolation Mounts

With the ECM location determined and the field fabricated bracket built, mount the ECM onto the new bracket.

There are four mounting points on the ECM, one at each corner. Mark each mounting point location on the bracket and drill a hole to accommodate a size M8 bolt that corresponds to each mounting point.
Use one 6V-5221 Bolt, two 9N-0869 Hard Washers, one 8T-9658 Spacer, two 8T-9655 Isolation Mounts, and one 3T-0852 Locknut at each mounting location of the ECM.
Ground the ECM.
One corner of the ECM includes a ground strap. If the ECM must be mounted to a non-conductive portion of the machine, use a ring lug and wire to connect the ground strap to the nearest ground point on the machine chassis. The conductive flat surface of the lug must be directly connected to a conductive surface that is bonded to the machine chassis.

Installation of the Electrical Harnesses

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Illustration 2	g06039730

All systems use the same harness to connect the transducers to the main harness. Use Illustration 2 as a guide.

Connecting the Low Flow Rate Transducers

Install the 451-4745 Wiring Harness on the ECM.

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Illustration 3	g03578441
Arrow on transducer indicates fuel flow. (1) Transducer (2) Location of the connector marked "A-C3" and "C-C3" of the 448-8685 Wiring Harness (3) Location of the connector marked "A-C2" and "C-C2" of the 448-8685 Wiring Harness (4) Location of the connector marked "A-C4" and "C-C4" of the 448-8685 Wiring Harness

Connect the three connectors of the 448-8685 Wiring Harness to the supply transducer. Refer to Illustration 3 for connector locations.
Connect the three connectors of the 448-8686 Wiring Harness to the return transducer. Refer to Illustration 3 for connector locations.
Note: Step 3 is not necessary if installing a single fuel flow transducer system.
Connect the 448-8685 Wiring Harness and the 448-8686 Wiring Harness to the 451-4745 Wiring Harness. If the 448-8685 Wiring Harness and/or the 448-8686 Wiring Harness are too short, then extension harnesses are available.
The 448-8685 Wiring Harness will connect to the "J-C5" connector of the 451-4745 Wiring Harness.
The 448-8686 Wiring Harness will connect to the "J-C6" connector of the 451-4745 Wiring Harness.
Note: Not all parts of Step 4 are necessary if installing a single fuel flow transducer system.
Note: The 3.048 m (10 ft) extension harness is part number 448-8687 Wiring Harness. The 6.096 m (20 ft) extension harness is part number 448-8688 Wiring Harness.
Provide positive battery voltage, ground, and key switch to connector J-C16 of the 451-4745 Wiring Harness. Positive battery voltage should be connected to a fuse protected source. The key switch input is the positive battery voltage signal provided when the ignition is turned on. For systems that do not have a key switch signal, this input should be tied to positive battery voltage.

Connecting the High Flow Rate Transducers

Install the 451-4745 Wiring Harness on the ECM.

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Illustration 4	g03578441
Arrow on transducer indicates fuel flow. (1) Transducer (2) Location of the connector marked "A-C3" and "C-C3" of the 448-8685 Wiring Harness (3) Location of the connector marked "A-C2" and "C-C2" of the 448-8685 Wiring Harness (4) Location of the connector marked "A-C4" and "C-C4" of the 448-8685 Wiring Harness

Connect the three connectors of the 469-0140 Wiring Harness to the supply transducer. Refer to Illustration 4 for connector locations.
Connect the three connectors of the 469-0141 Wiring Harness to the return transducer. Refer to Illustration 4 for connector locations.
Connect the 469-0140 Wiring Harness and the 469-0141 Wiring Harness to the 451-4745 Wiring Harness. If the 469-0140 Wiring Harness and/or the 469-0141 Wiring Harness are too short, then extension harnesses are available.
The 469-0140 Wiring Harness will connect to the "J-C5" connector of the 451-4745 Wiring Harness.
The 469-0141 Wiring Harness will connect to the "J-C6" connector of the 451-4745 Wiring Harness.
Note: The 3.048 m (10 ft) extension harness is part number 448-8687 Wiring Harness. The 6.096 m (20 ft) extension harness is part number 448-8688 Wiring Harness.
Provide positive battery voltage, ground, and key switch to connector J-C16 of the 451-4745 Wiring Harness. Positive battery voltage should be connected to a fuse protected source. The key switch input is the positive battery voltage signal provided when the ignition is turned on. For systems that do not have a key switch signal, this input should be tied to positive battery voltage.

Connecting the Fuel Consumption Monitoring System to a Network

The remaining connectors on the 451-4745 Wiring Harness may be used based on the use of Product Link or an existing network. The ECM can be connected to a network three different ways:

To a Product Link radio as a stand-alone network
To an existing network as a stub
To an existing network as an extension to the network

Connecting to a Cat^® Product Link Radio in a Stand Alone Network

Note: Refer to Section "System Schematic" for more wiring information.

Connecting to a Product Link radio in a stand-alone network will require the use of connector C-J15 of the 451-4745 Wiring Harness.

Connector C-J15 provides CDL, CAN (J1939), positive battery voltage, and a ground connection that can be used for connection to Cat ET or a Product Link radio.

Stand Alone Network with a Harness Length of 1.22 m (4 ft) or Less

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Illustration 5	g03713617
Stand alone network with the length of the J-C15 connection 1.22 m (4 ft) or less.

"CAN A RES2" can be used as installed in J-C11 as long as any connections to J-C15 are kept reasonably short (less than 1.22 m (4 ft). Refer to Illustration 5.

Stand Alone Network with a Harness Length More Than 1.22 m (4 ft)

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Illustration 6	g03713633
Stand alone network with the length of the J-C15 connection 1.22 m (4 ft) or more.

"CAN A RES2" will need to be moved If the connection to J-C11 is more than 1.22 m (4 ft). The resistor must be moved to the furthest point from the ECM. Refer to Illustration 6.

Connecting to an Existing Network as a Stub

Note: Refer to Section "System Schematic" for more wiring information.

Connecting to an existing network as a stub will require the use of connector C-J11 of the 451-4745 Wiring Harness.

Connector C-J11 provides a connection for CAN (J1939).

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Illustration 7	g03713654
Connection to an existing network as a stub. Both "CAN A RES1" and "CAN A RES2" removed.

Both resistors "CAN A RES1" and "CAN A RES2" would be removed and not used in this application. Refer to Illustration 7.

Connecting to an Existing Network as an Extension to the Network

Note: Refer to Section "System Schematic" for more wiring information.

Connecting to an existing network as an extension to the network will require the use of connector C-J11 of the 451-4745 Wiring Harness.

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Illustration 8	g03713658

The network terminating resistor to the current network would be removed and its socket used to connect to the ECM. The "CAN A RES2" would be removed and its empty socket used as a connection point to the network. Refer to Illustration 8.

Electrical Validation of the System

Conditions to Perform the Validation Procedure

Note: Before beginning the validation procedure, make sure that all the following conditions are as listed.

Remove the "J-C1" connector from the ECM and verify the following:

"J-C5" is connected to "A-C1"
"A-C2" is connected to Supply Speed Sensor 1
"A-C3" is connected to Supply Speed Sensor 2
"A-C4" is connected to Supply Temperature Sensor
"J-C9" is connected to "J-C13"
"J-C6" is connected to "C-C1"
"C-C2" is connected to Return Speed Sensor 1
"C-C3" is connected to Return Speed Sensor 2
"C-C4" is connected to Return Temperature Sensor
"J-C16" is disconnected
"J-C15" is disconnected
"CAN A RES1" is connected to "J-C3"
"CAN A RES2" is connected to "J-C11"

Power OFF Test

Speed Sensors Connections Test

Verify that the ignition is in the OFF position.
Connect a digital volt meter positive lead to "J-C1-68".
Connect the negative lead to the following pins:
- "J-C1-6"
- "J-C1-52"
- "J-C1-61"
- "J-C1-63"
Each measurement should have a resistance reading between 827k ohms and 863k ohms.

Temperature Sensors Connections Test

Verify that the ignition is in the OFF position.
Connect a digital volt meter positive lead to "J-C1-56".

Connect the negative lead to the following pins:

"J-C1-36"
"J-C1-37"

The target resistance depends on the current ambient temperature. Use Table 11 to determine the target resistance for a low flow rate transducer. Use Table 12 to determine the target resistance for a high flow rate transducer.

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Table 11
Temperature to Resistance Map for Low Flow Rate Temperature Sensor
Temp (°C)	Ohms	Temp (°C)	Ohms	Temp (°C)	Ohms	Temp (°C)	Ohms
-40	4.927	8	4.0735	56	1.828	104	0.5415
-39	4.922	9	4.036	57	1.786	105	0.528
-38	4.917	10	3.998	58	1.744	106	0.514
-37	4.9115	11	3.959	59	1.703	107	0.5015
-36	4.9055	12	3.9195	60	1.663	108	0.489
-35	4.8995	13	3.879	61	1.6235	109	0.477
-34	4.893	14	3.8375	62	1.5845	110	0.4655
-33	4.886	15	3.795	63	1.546	111	0.4535
-32	4.8785	16	3.7525	64	1.509	112	0.442
-31	4.871	17	3.7085	65	1.472	113	0.431
-30	4.863	18	3.664	66	1.436	114	0.4205
-29	4.8545	19	3.619	67	1.401	115	0.41
-28	4.8455	20	3.573	68	1.366	116	0.4
-27	4.836	21	3.5265	69	1.3275	117	0.3905
-26	4.8265	22	3.4795	70	1.2995	118	0.3805
-25	4.816	23	3.432	71	1.2665	119	0.372
-24	4.805	24	3.384	72	1.235	120	0.3625
-23	4.7935	25	3.3355	73	1.204	121	0.354
-22	4.7815	26	3.2865	74	1.174	122	0.345
-21	4.769	27	3.237	75	1.1445	123	0.3375
-20	4.756	28	3.1875	76	1.1155	124	0.3285
-19	4.742	29	3.1375	77	1.087	125	0.3205
-18	4.7275	30	3.0875	78	1.059	126	0.3135
-17	4.7125	31	3.037	79	1.032	127	0.3055
-16	4.6965	32	2.9865	80	1.006	128	0.2985
-15	4.68	33	2.9355	81	0.9805	129	0.2915
-14	4.663	34	2.885	82	0.9555	130	0.2845
-13	4.645	35	2.834	83	0.931	131	0.278
-12	4.6265	36	2.783	84	0.907	132	0.272
-11	4.607	37	2.7325	85	0.884	133	0.265
-10	4.5865	38	2.6815	86	0.861	134	0.2595
-9	4.5655	39	2.6315	87	0.839	135	0.253
-8	4.544	40	2.5805	88	0.818	136	0.2475
-7	4.521	41	2.5305	89	0.797	137	0.2415
-6	4.4975	42	2.481	90	0.776	138	0.236
-5	4.473	43	2.4315	91	0.757	139	0.2305
-4	4.448	44	2.382	92	0.737	140	0.226
-3	4.4215	45	2.3335	93	0.718	141	0.2205
-2	4.3945	46	2.285	94	0.7	142	0.215
-1	4.3665	47	2.237	95	0.682	143	0.21
0	4.3375	48	2.189	96	0.6645	144	0.2055
1	4.308	49	2.142	97	0.648	145	0.201
2	4.277	50	2.0955	98	0.631	146	0.1965
3	4.2455	51	2.0495	99	0.615	147	0.1925
4	4.213	52	2.004	100	0.5995	148	0.188
5	4.1795	53	1.959	101	0.584	149	0.1835
6	4.145	54	1.915	102	0.57	150	0.1795
7	4.1095	55	1.871	103	0.555

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Table 12
Temperature to Resistance Map for High Flow Rate Temperature Sensor
Temp (°C)	Ohms	Temp (°C)	Ohms	Temp (°C)	Ohms	Temp (°C)	Ohms
-40	33650.2	8	2193.5	56	287.6	104	60.6
-39	31494.9	9	2089.7	57	277.3	105	58.9
-38	29492	10	1991.4	58	267.3	106	57.2
-37	27628.3	11	1898.3	59	257.8	107	55.6
-36	25893.8	12	1810.1	60	248.7	108	54.1
-35	24279.1	13	1726.4	61	239.9	109	52.6
-34	22774.4	14	1647.1	62	231.5	110	51.2
-33	21372.7	15	1571.9	63	223.4	111	49.8
-32	20066.2	16	1500.6	64	215.7	112	48.4
-31	18846.7	17	1432.9	65	208.2	113	47.1
-30	17709.4	18	1368.5	66	201.1	114	45.8
-29	16647.7	19	1307.5	67	194.2	115	44.6
-28	15655.8	20	1249.5	68	187.6	116	43.4
-27	14728.9	21	1194.5	69	181.3	117	42.3
-26	13862.6	22	1142.1	70	175.2	118	41.1
-25	13052.6	23	1092.3	71	169.3	119	40.1
-24	12295	24	1045	72	163.7	120	39
-23	11585.6	25	1000	73	158.3	121	38
-22	10921.5	26	957.2	74	153.1	122	37
-21	10299.7	27	916.4	75	148.1	123	36.1
-20	9716.7	28	877.6	76	143.3	124	35.1
-19	9170.2	29	840.7	77	138.6	125	34.2
-18	8657.8	30	805.5	78	134.1	126	33.4
-17	8177.1	31	772	79	129.8	127	32.5
-16	7725.9	32	740	80	125.7	128	31.7
-15	7302.3	33	709.6	81	121.7	129	30.9
-14	6904.3	34	680.6	82	117.9	130	30.1
-13	6530.6	35	652.8	83	114.2	131	29.4
-12	6179.2	36	626.5	84	110.6	132	28.7
-11	5848.8	37	601.3	85	107.2	133	27.9
-10	5538	38	577.2	86	103.8	134	27.3
-9	5245.5	39	554.3	87	100.6	135	26.6
-8	4970.2	40	532.3	88	97.6	136	26
-7	4711	41	511.4	89	94.6	137	25.3
-6	4466.9	42	491.4	90	91.7	138	24.7
-5	4236.7	43	472.3	91	89	139	24.1
-4	4019.8	44	454	92	86.3	140	23.6
-3	3815.2	45	436.6	93	83.7	141	23
-2	3622.3	46	420	94	81.2	142	22.4
-1	3440.2	47	404	95	78.8	143	21.9
0	3268.3	48	388.6	96	76.5	144	21.4
1	3106	49	374	97	74.3	145	20.9
2	2952.7	50	360	98	72.1	146	20.4
3	2807.8	51	346.6	99	70	147	20
4	2670.9	52	333.8	100	68	148	19.5
5	2541.5	53	321.5	101	66	149	19
6	2419	54	309.7	102	64.2	150	18.6
7	2303.1	55	298.4	103	62.3

Power ON Test

Power, Ground, and Key Switch Connections Test

Connect "J-C16" to machine power, ground, and key switch.
Connect a digital volt meter negative lead to the machine chassis.
With the power OFF connect a digital volt meter positive lead to the "J-C1-2". The resistance should be less than three ohms and no voltage present.
With the power ON connect a digital volt meter positive lead to the "J-C1-1". The expected result is battery voltage.
With the power ON and key switch OFF, connect a digital volt meter positive lead to the "J-C1-3". The expected result is close to zero volts.

Communications Link Connections Test

Turn the key switch to the OFF position.
Connect the "J-C1" connector to the ECM.
Turn the key switch to the ON position.
Connect the Caterpillar Communications Adapter to "J-C15".
Connect to the ECM using Cat ET.
Set protocol option to J1939 using Cat ET, verify that one ECM is detected.
Start the engine and check each of the fuel line connections for leaks.
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Illustration 9 g06297057

Status Flow Rate screen.
Read Cat ET status screen to check that fuel flow is being reported for the supply transducer, "Engine Fuel Flow Rate 1", and the return transducer "Engine Fuel Flow Rate 2". Refer to Illustration 9. For small engines running at idle, it may take up to 10 seconds for the value to be updated.
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Illustration 10 g06297059

Status Temperature screen
Read Cat ET status screen to check that fuel temperature is being reported for the supply and return transducer. Refer to Illustration 10.
Move the throttle to run and observe that fuel consumption values update more frequently.
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Illustration 11 g06081539

Totals screen
Verify that the total fuel consumed is updating on the Totals screen. Refer to Illustration 11.

Transducer Installation / Position Check

After the transducers are installed and correct data is being read in Cat ET, check to see if the transducer wiring is connected to the correct transducer. Ensure that the temperature is being displayed in Cat ET. Remove the temperature connector from the supply transducer. Verify that the supply temperature in Cat ET changes to ambient room temperature. If the temperature shown for the return temperature reacts, then the harnesses for the supply and return transducers have been connected incorrectly. Exchange the harnesses and check the temperatures again.

Speed Sensor Connection Position Check

After the transducers are installed, verify that the correct data is being read in Cat ET. If the flow rate of the supply sensor wiring is not connected to the correct sensor, Cat ET will display the fuel flow rate as "unavailable". Swap the speed sensor connectors. Repeat for the return transducer.

Configuring the Number of Transducers

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Illustration 12	g06081543
Fuel Flow Configuration screen

The "Configuration" screen is used for setting the number of transducers used to one or two. If a dual fuel flow system is used, the number of transducers is automatically set to two by default. If a single flow system has been installed, it is important to set the number of fuel consumption monitoring transducers to one.

Configuring Engine Idle Flow Rate Threshold and Number of Transducers

A feature of the Fuel Consumption Monitoring System is the ability to measure fuel usage while the engine is at idle. To do this, the technician must run the engine at idle and read the current fuel consumption rate.

Turn on the engine and run the engine at idle to measure the Fuel Consumption Rate. Allow the engine to come up to operating temperature. While still connected to the machine, run the engine at idle and read the value of the Fuel Consumption Rate (supply flow rate — return flow rate) as displayed in Cat ET. Fuel consumption in the single transducer system is based only upon the supply flow rate. Record this value. Calculate an offset value of five to 10 percent of the Fuel Consumption Rate at idle. The calculation is Fuel Consumption Rate times 1.05 for five percent offset or 1.10 for 10 percent offset. Enter this value in the Cat ET configuration screen as the "Idle Fuel Consumption Rate Threshold". This value will be used as the threshold for the engine to be considered at idle. If the run time Fuel Consumption Rate is the Idle Fuel Consumption Rate value or less, then "Engine Idle Total Fuel Used" and "Engine Idle Total Hours" will be accumulated under the "Current Totals" screen of Cat ET.

The "Calibration" screen is used for setting the number of transducers used to one or two. If a dual fuel flow system is used, ensure that the number of transducers is set to two. When using a single flow system, make sure that the number is set to one.

More Cat^® Electronic Technician (Cat ET) Screens Used for the Fuel Consumption Monitoring System

Status Screen

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Illustration 13	g06297060
Status Flow Rate screen

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Illustration 14	g06081538
Status Temperature screen

The "Status" screen in Cat ET will display this value along with other run time parameters:

Total fuel used
Total fuel used at idle
Supply fuel temperature
Return fuel temperature for systems that have a return transducer installed
Current supply fuel flow rate
Current return fuel flow rate for systems that have a return transducer installed
Current difference between the supply and return fuel flow rates for systems that have a return transducer installed.

Current Totals Screen

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Illustration 15	g06081539
Total screen

The "Current Totals" screen in Cat ET will display:

Total fuel used
Total fuel used at idle
Total idle hours

Troubleshooting

System Schematic

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Illustration 16	g03590886

Fuel Measurement Module Diagnostics

The CDL CID for the Fuel Measurement Module ECM will be a 4520.

Speed Sensor Diagnostic Indicators

If the ECM is not able to obtain a valid differential signal from the sensor outputs a fuel volume speed sensor has failed. In this event, the ECM will raise a diagnostic message and transmit it on the main J1939 data link and the CDL bus. The diagnostic can be read in Cat ET on the "Status" screen. The harness connector in the table indicates the location of the errant sensor.

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Table 13
J1939 Diagnostic
Sensor Description	SPN	FMI	Harness Pin Number	Harness Connector
Engine Fuel Supply Flow Rate	2773	10 and 14	J1-6	A-C2
Engine Fuel Supply Flow Rate	2773	8	J1-52	A-C3
Engine Fuel Return Flow Rate	2774	10 and 14	J1-61	C-C2
Engine Fuel Return Flow Rate	2774	8	J1-63	C-C3

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Table 14
CDL Diagnostic
Sensor Description	DTC CID	FMI	Harness Pin Number	Harness Connector
Fuel Supply Flow Rotor Speed Sensor 1	4515	10 and 14	J1-6	A-C2
Fuel Supply Flow Rotor Speed Sensor 2	4516	8	J1-52	A-C3
Fuel Return Flow Rotor Speed Sensor 1	4517	10 and 14	J1-61	C-C2
Fuel Return Flow Rotor Speed Sensor 2	4518	8	J1-63	C-C3

If the fuel volume speed sensor detects an abnormal rate of change, a diagnostic of FMI 10, "Abnormal Rate of Change", will be reported on the J1939 data link and the CDL data link for the errant sensor. An "Abnormal Rate of Change" will be detected when the measured frequency is greater than the maximum flow rate for which the transducer is rated.

If the fuel volume speed sensor detects an abnormal frequency, pulse width or period, a diagnostic of FMI 8, "Abnormal Frequency, Pulse Width or Period", will be reported on the J1939 data link and the CDL data link for the errant sensor. This indicates a loose or pinched wire or an errant speed sensor. An abnormal frequency, pulse width, or period will be detected if the frequency reading indicates that the transducer has been installed backwards.

If the fuel volume speed sensor outputs a flow rate of 160 pps or more, a diagnostic with FMI 14 will be reported on the J1939 data link and the CDL. This indicates that the flow rate through the transducer is approaching the maximum flow rate.

Temperature Sensor Diagnostic Indicators

If a temperature sensor fails, the ECM raises a diagnostic message and sends it on the main J1939 data link and the CDL bus.

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Table 15

Sensor Description	J1939 SPN	CDL DTC CID	Harness Pin Number	Harness Connector
Fuel Flow Supply Temperature Sensor	2775	4519	J1-36	A-C4
Fuel Flow Supply Temperature Sensor	2776	1929	J1-37	C-C4

If a diagnostic of FMI 3, Voltage Above Normal, is reported on the J1939 data link or the CDL data link for the errant sensor, this indicates possible short to battery indicating a broken wire or defective sensor.

If a diagnostic of FMI 4, Voltage Below Normal, is reported on the J1939 data link or the CDL data link for the errant sensor, this indicates possible short to ground indicating a pinched wire or defective sensor.

Data Retention

The system is designed to monitor the fuel consumed by the engine, irrespective of time. If either transducer is replaced, the ECM will not reset the fuel volume values.

Replacing Failed Parts

The fuel volume transducer is a precision device. If the transducer experiences a failure in one of the sensors, the specific sensor can be replaced without impacting the calibration of the device.

Replacement part numbers are as follows:

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Table 16
Replacement Parts
Part Description	Low Flow Rate System	High Flow Rate System
Speed Sensor	384-3887 Speed Sensor Gp	384-3887 Speed Sensor Gp
Speed Sensor O-ring
Temperature Sensor	191-6587 Temperature Sensor Gp	238-0112 Temperature Sensor Gp
Temperature Sensor O-ring	214-7568 O-Ring Seal	214-7568 O-Ring Seal
Transducer	434-5030 Flow Meter Gp	434-5040 Flow Meter Gp

Replacing Failed Transducers

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Illustration 17	g03586151
Sample calibration certificate (1) Serial number (2) Temperature (3) K-factor (4) Frequency

Each Fuel Consumption Monitoring System will come from the manufacturer with the software flashed and the system configuration already programmed into the ECM. If this is a first-time installation, the configuration of the system has already been completed, and the 'Replacing Failed Transducers' section of this Special Instruction can be disregarded. The Replacing Failed Transducers section is intended for reference when installing a replacement for a failed transducer.

The following information is provided here in the event of a transducer failure. At that point, a new transducer must be installed and the corresponding calibration data must be updated using Cat ET. When the new transducer is received, a calibration data sheet will be included with the new transducer. The calibration certificate will indicate these values.

Flow transducer serial number
The temperature at which the calibration values were calculated
Seven corresponding K-factors (calibration factors) for each transducer
Seven corresponding frequencies for each transducer

Note: As the calibration data for a new transducer will be different than the calibration data for the failed transducer, the new transducer data must be entered in the order that they are listed, as there is a one to one correspondence between them the K-factors and the frequencies.

Refer to Illustration 17 for a sample calibration certificate.

Maintenance

Best operation and maintenance practices for the Fuel Consumption Monitoring System are as follows:

Operator visually inspects fuel lines and transducer connections daily to ensure that there is no leakage.
Technician manually inspects fuel lines and transducer connections weekly to ensure that there is no leakage.
Technician manually inspects harness and connections monthly.