Using the Caterpillar Fuel Flow Monitor System{0782, 1000, 1250} Caterpillar

1U5450, 1U5440 and 1U5430 Arrangements

Introduction

The Caterpillar Fuel Flow Monitor System is a versatile fuel flow measurement system, designed to help evaluate engine performance. This fuel flow monitor system uses two fuel flowmeters and a hand held monitor to:

* Measure fuel flow and fuel temperature of both supply and return-to-tank fuel lines.

* Calculate the fuel burn rate of the engine.

The Caterpillar Fuel Flow Monitor System can also be used as a single flowmeter measurement system on engines that do not have a fuel return line.

Information on the average and total fuel burned by the engine over a period of time is also provided by the hand held monitor.

State of the art turbine flowmeters are used with this system to measure fuel flow. These turbine flowmeters each contain a microprocessor that linearizes the output signals, and temperature corrects the flow rates to provide accurate fuel flow and fuel temperature data.

The output of the flowmeters is a digital signal that communicates directly with the fuel flow monitor.

The Fuel Flow Monitor System (FMS) is available in two sizes, to measure fuel flow on most Caterpillar engines.

The flowmeters connect directly to the hand held monitor. This monitor displays fuel flow and fuel temperature information.

In addition, the burn rate of the engine is displayed. Internal memories record the average fuel burn rate over a period of time and the total fuel burned. This information can be displayed in either Metric or English units.

Fuel Flowmeter Rework Program and Part Number Changes

Some of the componets in the Fuel Flowmeter Group have been reworked, at the factory, to improve reliability.

The reworked componets, in factory stock, have the new (replacement) part numbers.

The three main arrangements part numbers 1U5430, 1U5440 and 1U5450 have NOT been changed and can still be ordered.

The reworked componets can also be identified by the letter A stamped after the part number.

In the following list the left column is the original part number and the right column is the new (replacement) part number.

The part description remains the same.

1U5301 Supply Flowmeter Group (small) ... 4C9758

1U5302 Supply Flowmeter Group (small) ... 4C9759

1U5303 Supply Flowmeter Group (large) ... 4C9760

1U5304 Supply Flowmeter Group (large) ... 4C9761

8T9119 Flowmeter (small) ... 4C9762

8T9121 Flowmeter (large) ... 4C9763

1U5300 Monitor Group ... 4C9764

8T9177 Sight Glass (small) ... 1U9211

8T9176 Sight Glass (large) ... 1U9212

Components of the Fuel Flow Monitor System

1U5450 Complete Engine Test Arrangement

This arrangement consists of a complete system for small-to-large engines.

Operating Range:

11.4 lph (3 gph) - 3785 lph (1000 gph)

1. 4C9764 Fuel Flow Monitor Group. 2. 1U5299 Case Assembly. 3. 1U5305 Hose/Adapter Group (small). 4. 1U5306 Hose/Adapter Group (large). 5. 4C9759 Return Fuel Flowmeter Group (small). 6. 1U5420 Hose/Adapter Group (3600 Engines). 7. 4C9760 Supply Fuel Flowmeter Group (large). 8. 4C9758 Supply Fuel Flowmeter Group (small). 9. 4C9761 Return Fuel Flowmeter Group (large).

1U5430 Small to Medium Engine Fuel Flow Monitor Arrangement

Maximum Operating Range:

11.4 lph (3 gph) - 265 lph (70 gph).

These flowmeters can be used with the following Caterpillar engines:

* D300 Engine Family.

* 1100 Engine Family.

* 3200 Engine Family.

* 3300 Engine Family.

* 3400 Engine Family.

NOTE: Some earlier model D353, D379, D398 and D399 Engines have a fuel filter housing that is made of cast iron and a fuel flow rate of more than 265 lph (70 gph). This will make it necessary to use either the 1U5440 Flow Monitor Arrangement, or block the return fuel flow and use only the 4C9758 Supply Meter.

Refer to Fuel Filter Housing Identification (Early Model D300 Engine Family) in this manual.

1. 4C9764 Fuel Flow Monitor Group. 2. 1U5305 Hose/Adapter Group (small). 3. 4C9758 Supply Fuel Flowmeter Group (small). 4. 4C9759 Return Fuel Flowmeter Group (small).

1U5440 Medium to Large Engine Fuel Flow Monitor Arrangement

Maximum Operating Range: 151 lph (40 gph) to 3785 lph (1000 gph).

These flowmeters can be used with the following Caterpillar engines:

* D300 Engine Family.

* 3500 Engine Family.

* 3606 Engine.

* 3608 Engine.

Larger engines can be measured with these flowmeters by using a single flowmeter and recirculating the return fuel, and using a fuel cooler if required.

NOTE: Some earlier model D300 Series Engines have a fuel filter housing that is made of cast iron and a fuel flow rate of more than 265 lph (70 gph). This will make it necessary to use the 1U5440 Flow Monitor Arrangement.

Refer to Fuel Filter Housing Identification (Early Model D300 Family Engines) in this manual.

NOTE: Engines that are larger than the 3608 will require the use of four flowmeters, if fuel flow is more than 3790 lph (1000 gph). This is done by connecting two supply flowmeters in parallel and two return flowmeters in parallel. Two monitors are used and both burn rates are added together to obtain the total burn rate of the engine. Contact Caterpillar Service Technology Group for more details.

1. 4C9764 Fuel Flow Monitor Group. 2. 1U5306 Hose/Adapter Group (large). 3. 4C9760 Supply Fuel Flowmeter Group (large). 4. 1U5420 Hose/Adapter Group (3600 Engines). 5. 4C9761 Return Fuel Flowmeter Group (large).

Individual Groups Available

4C9764 Fuel Flow Monitor Group Components

1. 1U5299 Carrying Case Assembly (Includes foam insert). 2. 8T9300 Fuel Flow Monitor. 3. 8T9280 Fuel Flow Monitor Power Supply. 4. 5P7366 Power Cable for connection to machine battery. 5. 1U5297 Cable for connecting 8T9280 Power Supply to 8T9300 Monitor. 6. NEEG2499 Label for carrying case ... 4C9764 Fuel Flow Monitor Group. 7. Special Instruction ... SEHS8874 Using the Caterpillar Fuel Flow Monitor System.

Fuel Flowmeter Groups Available for use with the Fuel Flow Monitor Group

There are two sizes of flowmeters available for use with the Fuel Flow Monitor Group.

Refer to the engine lists and specifications shown to determine which flowmeter group is required for your application.

Attempting to use a flowmeter group that does not have the required flow range, will result in an underflow, or overflow condition and no fuel flow information.

Small Flowmeter Groups

Maximum Operating Range:

11 lph (3 gph) - 265 lph (70 gph)

These flowmeters can be used with the following Caterpillar engines.

* D300 Engine Family.

* 1100 Engine Family.

* 3200 Engine Family.

* 3300 Engine Family.

* 3400 Engine Family.

NOTE: Some D300 Series Engines have a fuel filter housing that is made of cast iron and a fuel flow rate of more than 265 lph (70 gph). This will make it necessary to use either the 1U5440 Flow Monitor Arrangement, or block the return fuel flow and use only the 4C9758 Supply Meter.

Refer to Fuel Filter Housing Identification (Early Model D300 Family Engines) in this manual.

1. 4C9758 Supply Fuel Flowmeter Group (small). 2. 4C9759 Return Fuel Flowmeter Group (small).

Large Flowmeter Groups

Maximum Operating Range:

151 lph (40 gph) - 3785 lph (1000 gph)

These flowmeters can be used with the following Caterpillar engines.

* D300 Engine Family.

* 3500 Engine Family.

* 3606 Engine Family.

* 3608 Engine Family.

NOTE: Some earlier model D300 Series Engines have a fuel filter housing that is made of cast iron and a fuel flow rate of more than 265 lph (70 gph). This will make it necessary to use either the 1U5440 Flow Monitor Arrangement, or block the return fuel flow and use only the 4C9758 Supply Meter.

Refer to Fuel Filter Housing Identification (Early Model D300 Family Engines) in this manual.

Larger engines can be measured with these flowmeters by using a single supply flowmeter, and recirculating the return fuel using a fuel cooler and pump.

1. 4C9760 Supply Fuel Flowmeter Group (large). 2). 4C9761 Return Fuel Flowmeter Group (large).

Optional Items for use With the Fuel Flow Monitor System

(1) 8T9276 AC Power Supply, 110/220 Volts AC, 50/60 Hz:

Used for powering diagnostic service tools, including the fuel flow monitor system. It supplies 11 to 20 Volts DC, at 1.2 Ampere maximum current.

(2) 1U5299 Carrying Case Assembly:

Carrying case with foam insert holds two flowmeter groups and a monitor group.

(3) 1U5298 Cable, 5.5 m (18 ft):

Used to connect fuel flowmeter groups to hand held 8T9300 Fuel Flow Monitor. One cable is supplied with each fuel flowmeter group.

(4) 6V2198 Extension Cable, 5.5 m (18 ft):

This cable is used for fuel flowmeter groups. (This cable is also used in the 6V3121 Multitach Group).

(5) 1P7408 Thermo-Hydrometer:

Range is 29° to 41° API.

(6) 5P2712 Thermo-Hydrometer:

Range 39° to 51° API.

(7) 1P7438 Beaker:

This beaker is used for fuel density tests.

Additional Items Available NOT Shown

8T9295 Magnetic Holding Base (For 8T9300 Monitor).

Metal Sight Glass Replacements:

Refer to the replacement parts list, in this manual, for the specific flowmeter group.

Aluminum Glass Sight Glasses:

Small ... 1U9211

Large ... 1U9212

Hose/Adapter Groups

These groups are used to connect the flowmeter groups to the engine. They provide the basic components needed to connect the respective size flowmeter groups to Caterpillar engines.

1U5305 Hose/Adapter Group (Small)

This hose/adapter group is for use with the 4C9758 and 4C9759 Flowmeter Groups.

1U5306 Hose/Adapter Group (Large)

This hose/adapter group is for use with the 4C9760 and 4C9761 Flowmeter Groups.

1U5420 Hose/Adapter Group - 3606/3608 Engines

This hose/adapter group is for use with large flowmeter groups.

Optional Hose Coupling Adapters for use With the Fuel Flow Monitor System

Use these adapters to connect the flowmeter hoses to the fuel lines of Caterpillar products that use O-Ring Face Seals, instead of JIC fittings on the fuel lines. The N Series tractors will use these fittings.

Specifications

Specifications for the Fuel Flow Monitor System

These specifications are for the 4C9764 Monitor Group and the Fuel Flowmeter Groups that follow, when they are used as a system to measure diesel fuel flow at 35° API fuel density.

Measuring Range and Accuracy

All accuracies that follow are the stated value ± one display digit.

One Small Flowmeter System Range and Accuracy

A single flowmeter system using the 4C9758 Supply Flowmeter Group only, with the 8T9300 Monitor:

* 11.4 lph (3 gph) to 22.7 lph (6 gph) ± 1% of reading.

* 22.7 lph (6 gph) to 227 lph (60 gph) ± 0.5% of reading.

* 227 lph (60 gph) to 265 lph (70 gph) ± 1% of reading.

One Large Flowmeter System Range and Accuracy

A single flowmeter system using the 4C9760 Supply Flowmeter Group only, with the 8T9300 Monitor:

* 190 lph (50 gph) to 227 lph (60 gph) ± 1% of reading.

* 227 lph (60 gph) to 2271 lph (600 gph) ± 0.5% of reading.

* 2271 lph (600 gph) to 3785 lph (1000 gph) ± 1% of reading.

Two Flowmeter System Burn Rate Range:

Small Flowmeters: 0 to 265 lph (0 to 70 gph).

Large Flowmeters: 0 to 2482 lph (0 to 655 gph).

Two Flowmeter System Accuracy - 1U5430, 1U5440, or 1U5450 Arrangements

Range is the same as that given for the single flowmeter systems.

A two flowmeter system uses a:

* 4C9758 Supply Fuel Flowmeter Group (small) and 4C9759 Return Flowmeter Group (small) ... or

* 4C9760 Supply Fuel Flowmeter Group (large) and 4C9761 Return Fuel Flowmeter Group (large) with the 8T9300 Monitor.

The accuracy of a two flowmeter system will vary, depending on the amount of fuel being used in relation to the amount of fuel being returned to the tank.

The amount of error is the same as a single flowmeter system when no fuel is returned to the tank (when all supply fuel is burned by the engine).

The error increases as more fuel is returned to the tank (when less of the supply fuel is burned by the engine).

The worst case accuracy for any supply to return rate reading combination, can be determined by using the following formula:

(.5 × Supply Rate) + (.5 × Return Rate) ÷ Burn Rate = ± Percent of Reading Maximum Error

The example that follows illustrates the formula:

Supply Rate = ... 60 lph (16 gph)

Return Rate = ... 30 lph (8 gph)

Burn Rate = ... 30 lph (8 gph)

NOTE: The Burn Rate in this example is 1/2 the Supply Rate.

(.5 × 16 gph) + (.5 × 8 gph) ÷ 8 = 8 + 4 ÷ 8 = 12 ÷ 8 = ± 1.5% of Reading Maximum Error.

Fuel Temperature Range:

-25° C to 60° C (-13° F to 140° F)

Fuel Temperature Accuracy:

1° C (2° F) ... This is providing that fuel has been flowing through the flowmeter long enough to stabilize the reading.

Arrangement Weights:

1U5450 ... 36 Kg (78 lbs) Total

1U5430 ... 17 Kg (37 lbs) Total

1U5440 ... 20 Kg (45 lbs) Total

Specifications for the 4C9758, 4C9759, 4C9760 and 4C9761 Fuel Flowmeter Groups.

Flowmeter Type:

Turbine type flowmeter with microprocessor linearized and temperature corrected digital output signal.

Output Signal:

Digital signal current loop, 0 to 20ma. 19,200 baud rate.

Flow Sensing Method:

Stainless steel turbine blades with radio frequency pickoff.

Flowmeter Case Material:

Black Anodized 2040 Aluminum.

Group Components:

Flow straightener, turbine meter, sight glass, accumulator, and fittings.

Operating Temperature Range:

Ambient air temperature and fuel temperature: -18°C to 60°C (0°F to 140°F).

Temperature Readout Range:

-25°C to 100°C (-13°F to 212°F).

Storage Temperature Range:

-40°C to 100°C (-40°F to 212°F). roy

Vibration:

Designed to be mounted on operating Caterpillar products.

Flowmeter Power:

Supplied by 8T9300 Fuel Flow Monitor only.

Maximum Operating Pressure:

1379 kPa (200 psi).

Bore Size:

Small Flowmeter ... 6.4 mm Ø (.25 in Ø).

Large Flowmeter ... 19.1 mm Ø (.75 in Ø).

Flow Connections:

Small Flowmeter Group 37° flare, Size 8 Female fitting.

Large Flowmeter Group ... 37° flare, Size 16 Female fitting.

Electrical Connections (Six Pin sealed connector):

Flowmeter ... MS 3112F-10-2P.

Flowmeter Cable ... MS 3116F-10-65.

Group Size:

Small Flowmeter ... 432 x 216 x 64 mm (17 x 8.5 x 2.5 in).

Large Flowmeter ... 533 x 216 x 64 mm (21 x 8.5 x 2.5 in).

Group Weight:

Small Flowmeter ... 14 kg (30 lbs).

Large Flowmeter ... 15 kg (33 lbs).

Specifications for the 8T9300 Fuel Flow Monitor Only

NOTE: These are not Flowmeter specifications.

Power supplied by the 8T9280 Power Supply.

Maximum Display Range:

0 to 19,999

Burn Rate Display Range:

0 to 2396 lph (0 to 655.3 gph).

Average Rate Display Range:

0 to 2396 lph (0 to 655.3 gph.

Maximum Hours To Full Average Memory:

11930 ÷ Average Rate in gph = Maximum Hours.

Total Fuel Burn Quantity Display Range:

0 to 19,999 liters (0 to 19,999 gallons).

Display Resolution:

SUPPLY RATE, RETURN RATE:

0 to 1999.9 lph = ... 0.1 lph

(0 to 1999.9 gph = ... 0.1 gph)

(2000 to 19999 lph = ... 1 lph)

BURN RATE, BURN AVERAGE:

0 to ± 37.81 lph = ... .01 lph

± 37.81 to 2480.3 lph = ... 0.1 lph

(0 to ± 9.99 gph = ... 0.01 gph)

(± 10.0 to ± 655.3 gph = ... 0.1 gph)

BURN TOTAL:

0 to 756.0 L = ... 0.1 L

756.9 to 19,999 L = ... 1 L

(0 to 199.99 Gal. = ... 0.01 Gal.)

(200.0 to 1999.9 Gal. = ... 0.1 Gal.)

(2000 to 19999 Gal. = ... 1.0 Gal.)

Display Update Rate:

Once each second.

Burn Memory Overflow:

When the stored burn total reaches 19,999 gallons, the memory will start over at 0 (zero) and OFL flashes alternately between readings.

Liters total will stop at 19,999 Liters and display will flash OFL when Total Liters is selected. Liters will not start over.

Error Codes:

Refer to Monitor Use Instructions in this manual.

Negative Flow Rates:

Refer to Monitor Use Instructions in this manual.

Operating Temperature Range:

-18° C to 60° C (0°F to 140° F).

Storage Temperature Range:

-40° C to 100° C (-40° F to 212° F).

Monitor Size:

190 x 112 x 40 mm (7.5 x 4.4 x 1.6 in).

Monitor Weight:

.57 kg (.25 lbs).

Power Up Select

Internal switches select the following parameters after power is applied to the monitor:

* One flowmeter (supply only) or, two flowmeters (S & R)

* °C or °F.

* Liters and lph or gallons and gph.

Power:

Supplied by 8T9280 Power Supply.

Power Connector:

On Monitor ... Three Pin Male-MS3102A-10SL-3P.

Cable ... MS3106A-10SL-3S.

Flowmeter Connectors (2):

On Monitor ... Switchcraft PREH 57GB5F.

Cable ... Switchcraft PREH 05BL5M.

Specifications for 8T9280 Monitor Power Supply

Type of Power Supply:

DC to DC switching converter.

Input Voltage Range:

11 to 40 VDC.

Input Current:

1.2 Ampere maximum.

Output Voltage:

12 VDC.

Output Current:

1.0 Ampere maximum.

Line Regulation:

.035 Volts maximum.

Load Regulation:

.035 Volts maximum.

Controls and Indicators on the 8T9300 Fuel Flow Monitor

The illustration that follows shows the location of the indicators and touch type switches on the front of the 8T9300 Fuel Flow Monitor.

NOTE: The touch switches must be pressed and held until the display shows a change has been made.

Controls and Indicators on 8T9300 Fuel Flow Monitor

(1) DIGITAL DISPLAY: The LCD (liquid crystal display) has automatic decimal point positioning, with arrow indicators to show which functions are being used and to indicate the units of the number displayed.

The display will always be ON whenever power is applied to the indicator.

Front Panel Switches

(2) METER SELECT: This switch must be pressed at the same time as SUPPLY/S & R switch (3), to select either one flowmeter or two flowmeter operation. This is to prevent accidental switching of functions.

(3) SUPPLY/S & R: When this switch is pressed at the same time as METER SELECT switch (2), it will select either:

* SUPPLY METER (20) (one flowmeter operation) ... or

* SUPPLY & RETURN METERS (26) (for two flowmeter operation).

Pressing both switches again will change to the alternate selection. An arrow on the display will indicate if SUPPLY METER (20) or SUPPLY & RETURN METERS (26) are being used.

(4) °C/°F: This switch operates ONLY when fuel temperature is being displayed.

The switch changes the temperature value on the display from degrees Centigrade to degrees Fahrenheit, when either the SUPPLY TEMP or RETURN TEMP is being displayed:

* A letter C on the display following the temperature value indicates degrees Centigrade.

* A letter F on the display following the temperature value indicates degrees Fahrenheit.

* Pressing the switch again will change to the other value.

(5) LIT/GAL: This switch will operate ONLY when a fuel function is being displayed.

Use this switch to change the value shown on the display for all fuel flow information, from LITERS (24) and LPH (22) to GALLONS (25) and GPH (23).

Arrows on the display will indicate which of these units has been selected whenever fuel information is being displayed.

Pressing this switch again will change the unit display.

(6) SUPPLY TEMP: Used to indicate the temperature of fuel in the supply flowmeter. An arrow will appear on the display next to SUPPLY (14) and TEMP (21). A C or F following the value will indicate either degrees Centigrade or Fahrenheit.

(7) RETURN TEMP: Used to indicate the temperature of fuel in the return flowmeter.

An arrow will appear on the display next to RETURN (15) and TEMP (21).

A C or F following the value will indicate degrees Centigrade or Fahrenheit.

This switch will NOT operate if SUPPLY METER (20) arrow is ON (in single flowmeter mode).

(8) SUPPLY RATE: Use this switch to indicate the flow rate of fuel in the supply line.

An arrow will appear on the display next to SUPPLY (14).

Another arrow will indicate either LPH (22) (Liters Per Hour) or GPH (23) (Gallons Per Hour).

UFL (UnderFlow) will appear on the display if there is no flow through the flowmeter, or if flow is below minimum.

OFL (OverFlow) will appear on the display if the maximum flow range of the flowmeter has been exceeded.

If the flowmeter is not connected (no communications) UUUU will appear on the display.

(9) RETURN RATE: Use this switch to indicate the flow rate of fuel in the return line, if a return flowmeter is being used (two flowmeter system).

This switch will NOT operate if SUPPLY METER (20) arrow is ON (in single flowmeter mode).

An arrow will appear on the display next to RETURN (15).

Another arrow will indicate either LPH (22) (Liters Per Hour) or GPH (23) (Gallons Per Hour).

UFL (UnderFlow) will appear on the display if there is no flow through the flowmeter, or if flow is below minimum.

OFL (OverFlow) will appear on the display if the maximum flow range of the flowmeter has been exceeded.

If the return flowmeter is underflow or overflow when SUPPLY RATE is being viewed, either UFL or OFL will flash on the display and RETURN (15) arrow will be ON, whenever these letters appear.

If the flowmeter is NOT connected (no communications) UUUU will appear on the display.

(10) HOLD/CLEAR: This switch has two functions.

When it is pressed alone (with no other switch) it will hold the reading on the display.

An arrow will appear at the DISPLAY HOLD (19) location. When the display is being held, none of the other switches will operate.

When the switch for HOLD/CLEAR (10) is pressed again, the display will CLEAR and a new current value will be displayed.

The HOLD/CLEAR switch (10) also has an added feature:

* It prevents accidental clearing of BURN AVG (11) and BURN TOTAL (12) memories.

Two switches MUST be pressed at the same time. Refer to PRESS BOTH TO CLEAR AVERAGE OR TOTAL under switch (10), (11) and (12).

(11) BURN AVG: This switch will indicate the average burn rate for the engine since the average memory was last cleared.

Arrows will appear next to AVG BURN (16) and LPH (22) (Liters Per Hour), or GPH (23) (Gallons Per Hour).

The average value can be cleared from memory by pressing HOLD/CLEAR switch (10), while holding down BURN AVG switch (11).

After clearing, the average memory immediately starts recording the new average value.

(12) BURN TOTAL: This switch will indicate the total fuel burned by the engine since the burn memory was last cleared.

Arrows will appear next to TOTAL BURN (17) and LITERS (24) or GALLONS (25).

The total value can be cleared from memory by pressing HOLD/CLEAR switch (10), while holding down BURN TOTAL switch (12).

After clearing, the new total value will immediately start recording in memory.

(13) BURN RATE: This switch will indicate the current burn rate on the display.

Arrows will appear next to RATE BURN (18) and either LPH (22) (Liters Per Hour) or GPH (23) (Gallons Per Hour).

If only a supply flowmeter is being used (single flowmeter operation):

* The flow through it will be the burn rate.

If both a supply and return flowmeter are being used (two flowmeter operation):

* The monitor will subtract the flow through the return flowmeter from the flow through the supply flowmeter and show the result as the burn rate.

A (-) sign in front of the burn rate indicates the return rate is higher than the supply rate. This can happen for short periods of time when the engine fuel supply is quickly shut off.

Powering the Fuel Flow Monitor System

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NOTICE
Because the 8T9300 Monitor does not have an internal power supply that is large enough to power the fuel flowmeters, the external 8T9280 Fuel Flow Monitor Power Supply MUST always be used to power the monitor. DO NOT connect the 8T9300 Monitor directly to any other voltage source, or damage may result.

8T9280 Fuel Flow Monitor Power Supply

There are two methods of powering the 8T9280 Fuel Flow Power Supply:

* External 11 to 40 Volts DC from the machine's or engine's battery.

* AC power operation using optional 8T9276 Power Supply.

Connecting the 8T9280 Power Supply to the Monitor

1. Connect the female end of a 1U5297 Cable (7) to EXTERNAL POWER SUPPLY connector (5) on the Fuel Flow Monitor.

Connect the other end to OUTPUT TO MONITOR connector (3) on 8T9280 Power Supply (1).

2. Connect the 5P7366 Power Cable (6) to the INPUT 11-40 VDC connector on 8T9280 Power Supply.

3. When using the battery on a machine or engine as the power source, power the monitor by connecting one of the power cable clips to the frame of the machine.

Connect the other clip to the battery positive terminal.

NOTE: The supply is non-polarized so either clip can be connected to either the positive or the machine frame.

4. If the machine is equipped with a disconnect switch, it must be turned to the ON position to supply power to the monitor.

Once power has been supplied, lift the handle on POWER ON switch (2).

The POWER ON indicator (4) should light and an indication should be seen on the monitor display.

AC Power Operation Using 8T9276 Optional AC Power Supply

1. Move switch (1) on the rear of 8T9276 AC Power Supply (2) to indicate the correct AC line voltage that is to be used:

* USA ... 120 VAC

* Most other countries ... 240 VAC

2. Connect AC Power Supply connector (4) to the INPUT 11-40 VDC connector on 8T9280 Monitor Power Supply (6).

Plug the AC power cord (3) into an AC outlet.

NOTE: For operation outside the USA, an AC power plug adapter may be required.

3. After AC power is applied, lift up on POWER ON switch handle (5).

The POWER ON indicator should light, and an indication should be seen on the monitor display.

Internal Fuse Test/Replacement

If the 8T9300 Fuel Flow Monitor will not operate when power is applied, the internal fuses may be burned out (broken filament).

Use the following procedure to test/replace the fuses.

NOTE: Remove all cables from the power supply before proceeding.

First Fuse Test

1. Remove six screws (1) from the rear cover. Remove cover (2) from the monitor.

2. Locate two fuses (3) on the printed circuit board directly behind the EXTERNAL POWER SUPPLY connector.

Use a 6V3030, 6V7800, or 6V7070 Digital Multimeter to test the fuses.

NOTE: The fuses can be left in their holders for the test.

Set the multimeter on the 200 Ohm scale to check the continuity between the two legs of the fuse.

If the fuse is good (reusable) the resistance will be <1 ohm (less than 1 ohm).

A defective fuse will measure infinite Ohms (OL on the multimeter display) and should be replaced. Be sure to test both fuses.

If a fuse is defective, install either an 8K4644 Fuse, or a 1 Amp, 250 Volt fuse of the same type as the original fuse.

Fuse Removal

If the monitor still will not operate with good fuses when connected to the 8T9280 Power Supply, fuse (4) on the front of the power supply must be tested.

3. To remove this fuse, turn the fuse cap to the left one-half turn and pull the fuse free.

Second Fuse Test

Use a 6V3030, 6V7800, or 6V7070 Digital Multimeter to test the fuses.

Set the multimeter on the 200 Ohm scale to check the continuity between the two legs of the fuse.

If the fuse is good (reusable) the resistance will be <1 ohm (less than 1 ohm).

A defective fuse will measure infinite Ohms (OL on the multimeter display) and should be replaced.

If the fuse is defective, install use a 4 AMP 3AG 250 Volt SLO BLO Fuse as a replacement. The Littelfuse type no. is 313004.

Operation Instructions

The Caterpillar Fuel Flow Monitor System is capable of providing very accurate fuel flow measurements on diesel engines.

However, to provide accurate information it must be correctly installed and correctly used. To obtain accurate data, the information that follows should be carefully observed.

NOTE: When installing the fuel flowmeter(s), a primary fuel filter should always be installed ahead of the flowmeters. This will prevent any contamination or dirt particles that may be in the fuel, from getting into the flowmeter bearings and causing the turbine rotor to stick.

Selection of a One Flowmeter or a Two Flowmeter System

The first step in using the Caterpillar Fuel Flow Monitor System is to determine the correct flowmeter arrangement that is to be used.

The Caterpillar Fuel Flow Monitor System has been designed to be operated as either a one flowmeter (supply only), or a two flowmeter (supply and return) fuel measurement system.

The two flowmeter system is normally the most preferred because of convenience of hookup and ease of reading.

The one flowmeter system also has advantages and it MUST be used on certain engines.

In addition to checking fuel flow on Caterpillar engines, the capability of operating with either one or two flowmeters permits the measurement of fuel flow on most competitive diesel engines.

The main factor that determines the system to be used is the amount of fuel that is returned to the fuel tank by the engine fuel system.

If the engine does not have a fuel return line, or if the fuel return line can be plugged during the test, then only one flowmeter is required.

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NOTICE
On some engines the return fuel is used for cooling and lubricating the fuel pump. Damage to the engine could result if the return line is plugged.

A pump and/or fuel cooler may be required if the return line is plugged.

Normally, if an engine has a return line that returns at least 11.3 lph (3 gph) (the minimum flow for small flowmeters) to the tank, then a two flowmeter system should be used.

Most Caterpillar engines have a return line that returns enough fuel to the fuel tank to permit the use of the two flowmeter system.

Listed below are the advantages and disadvantages of each type of system.

Two Flowmeter System

Advantages:

* Most preferred method for engines with a fuel return line.

* Will display burn rates down to 0 (zero).

* Easy hookup ... can be connected on supply lines.

* Engine fuel system does not have to be altered.

Disadvantages:

* Two flowmeters required.

* Accuracy is dependent on the amount of fuel burned in relation to flow volume.

One Flowmeter System

Advantages:

* Required method for engines with no return fuel line.

* Required method for engines with less than 11.3 lph (3 gph) return fuel flow rate (minimum flow rate for small flowmeters).

* Accuracy of test for all flow rates is constant (the same as the accuracy of the flowmeter used).

Disadvantages:

* Can not be used on some engines by blocking return fuel line unless a fuel cooler is used or, engine will be damaged.

* Will not read burn rates to 0 (zero) (minimum flow rate for small flowmeters is 11.3 lph (3 gph).

* Hookup is more complicated and costly when return fuel is involved.

Selection of Flowmeter Size

1. The Caterpillar Fuel Flow Monitor System has two different sizes of flowmeters (one size for small engines and one size for larger engines).

Refer to Components of the Fuel Flow Monitor System in this manual, for the capacity of each size and to determine which of the flowmeters to use.

Caterpillar engine adaptability is also given for each flow monitor arrangement.

2. If an engine other than a Caterpillar engine is to be measured, determine its approximate fuel flow range if possible.

Choose a flowmeter based on this flow. If this is not possible, determine which Caterpillar engine is closest to the horsepower rating of the engine, and choose the flowmeter for that size Caterpillar engine.

Two Flowmeter (Supply and Return) Installation Instructions

Use the following procedure to connect the supply and return flowmeter groups into the engine fuel system.

Although every engine installation can not be covered here, this procedure will give the basic connection method for a two flowmeter system.

Refer to the following illustration during the installation procedure.

Some of these parts may be located on the engine. 1. Caterpillar Return Fuel Flowmeter Group. 2. Fuel return line. 3. Diesel fuel tank. 4. Primary fuel filter. 5. Caterpillar Supply Fuel Flowmeter Group. 6. Fuel transfer pump. 7. Fuel filter. 8. Fuel supply line. 9. Fuel injection pump.

This illustration shows the fuel flowmeter groups installed in the best locations. The supply fuel flowmeter group is between the primary fuel filter and the fuel transfer pump. The return fuel flowmeter group is located in the return to tank fuel line. Other locations are discussed in the information that follows.

1. Compare the fuel system diagram shown, to the actual fuel system on the engine to be tested.

Note the location of the fuel supply and return lines. Check to see if there is clearance and easy access to permit installation of the flowmeter groups.

The flowmeter groups are installed by using hoses to connect into the fuel lines, with the flowmeters located at the end of the hoses.

If the location for the supply flowmeter group is not accessible, it can be installed in alternate locations as follows:

NOTE: Two types of fuel transfer pumps are used on Caterpillar engines. These pumps are identified as gear type and piston type.

Refer to Identification of Fuel Transfer Pump, in this manual, to identify the type of fuel transfer pump on the engine to be tested.

* If the engine has a gear type fuel transfer pump, the flowmeter can be installed in the line between its output and the secondary fuel filter of the engine.

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NOTICE
Do not install the flowmeter after the output of a piston type fuel transfer pump. The pulsations from a piston type fuel transfer pump will cause inaccurate fuel readings.

* On engines that have a gear type fuel transfer pump, the flowmeter may also be installed between the fuel filter and fuel injection pump.

NOTE: If the flowmeter is installed at this location, extreme care must be taken to not contaminate the fuel injection pump during installation and removal, or damage to the pump may result.

2. Select the hoses and fittings needed to make the connections from the specific hose/adapter group. (There are many different sizes and configurations for fuel lines and fittings.)

The hose/adapter groups include most parts needed for connection to Caterpillar engines.

Special fittings may be required for installation on engines other than Caterpillar engines.

These special fittings can be obtained from an industrial supply company, or from the engine dealer.

The connections to the flowmeter groups are standard 37° flare fittings.

3. Connect and tighten the hoses to the flowmeter group. If the flowmeter already has fuel in it, keep the end of the meter upright and put a cap on one end of the hose before connecting it to the flowmeter.

Usually a 0.3 m (1 ft) long hose can be used on one end and a 1 m (3 ft) long hose on the other end. Tighten the hose fittings so they will not leak.

4. Close the fuel shutoff valve at the fuel tank. Use tie straps to attach the flowmeter to the engine, near the installation location.

The flowmeters must be positioned so they will be full of fuel when the engine is running. This can be done by mounting the flowmeter so the flow direction arrow points UP at an angle that is 45° to 90° from the horizontal position.

5. Clean all dirt and contamination from the fitting and the area on the engine where the fuel line will be disconnected.

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NOTICE
Care must be taken so no dirt or paint is permitted to enter the fuel line. The turbine in the flowmeter may stick and give inaccurate results if any contamination enters the flowmeters.

Loosen and remove the fitting connecting the fuel lines.

Some installations require removal of a fuel line. In some other installations, the fuel line that is disconnected may be connected to the flowmeter.

Install the flowmeter lines making sure the fuel flow arrow on the flowmeter group points in the same direction that fuel will be flowing.

When installed in the correct direction, the accumulator will always be on the end of the flowmeter that connects with the engine fuel injection pump.

Tighten the hose fittings so they will not leak.

Purge Air From Flowmeters

For the flowmeters to be accurate, all air must be removed from them. Inspect for air trapped in the flowmeters by observing the sight glass and rocking the flowmeter back and forth, if possible.

A small amount of air can be removed by running the engine, but this requires a considerable amount of time to purge the air out of the fuel system.

6. Several methods, dependent on the type of fuel system, can be used to purge the air from the fuel:

* Open the fuel shutoff valve at the fuel tank

* Loosen a fuel line fitting and use the fuel priming pump to pressurize the fuel system.

* Tighten fitting after air has been purged.

This method will reduce the aeration.

3100 and 3500 Family of Engines

Some engines, 3100 Family and slow speed rated 3500 Family engines, may require different methods and/or equipment to reduce aeration:

* Install a 3/4 inch gate valve AFTER the return flowmeter to restrict the return line.

* Open the gate valve.

* START engine and close the gate valve until a maximum of 80 psi fuel pressure is reached.

As the gate valve is closed the aeration, with a light behind the sight glass should be visibly reduced.

An alternate method is to:

* Install a 20 psi pressure relief check valve AFTER the return flowmeter.

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NOTICE
Do NOT completely shut OFF the engine return fuel flow. Monitor the fuel system pressure BEFORE the restriction so that it does NOT exceed 80 psi. Failure to do so may cause engine damage.

If these methods and/or equipment does not reduce aeration to an acceptable level a De-Aerator Tank may be required.

Refer to NEHG3563 (1/90) ... Tool Announcement

7. Use the 1U5298 Cables to connect the fuel flowmeters to the fuel monitor.

Connect the supply flowmeter to the SUPPLY METER connector and the return flowmeter to the RETURN METER connector, on the top of 8T9300 Fuel Flow Monitor.

Use 6V2198 extension cables if required for more length.

To provide power for the monitor, refer to Powering the Fuel Flow Monitor System in this manual.

8. Start the engine and check for fuel leaks. Correct any leaks that are found.

Check for air in the fuel by observing the fuel flow through the sight glass on each flowmeter.

If a large amount of air is present, the fuel may appear milky white. If only a small amount of air is present, small bubbles can be seen in the fuel.

To eliminate either of these situations:

* Make sure all fittings are tight ... and

* Run the engine until the fuel is free of air bubbles.

A small leak on the fuel supply line will draw air into the fuel when the engine is running. This can usually be corrected by tightening a fitting.

It may be impossible to get all air bubbles out of the fuel. A few very small bubbles will not affect the readings enough to cause a large error, however, any air in the fuel causes some error in the readings.

Some other engine manufacturers engines may run with air in the return fuel lines. This will require an air separator system to remove the air from the fuel before a test can be made.

9. Run the engine at High Idle speed and observe the flow readings on the monitor.

Refer to Using the 8T9300 Fuel Flow Monitor in this manual for more information on obtaining the flow readings.

Before recording flow data, wait until the readings have stabilized. This may take several minutes. If the readings do not stabilize, check for air in the fuel lines.

One Flowmeter Installation Instructions

NOTE: One flowmeter installation can only be used on certain engines.

Refer to Selection of a One Flowmeter or a Two Flowmeter System in this manual before installing the flowmeter.

Use the procedure that follows to connect and use a one flowmeter supply line installation to measure fuel flow.

Although every engine installation can not be described here, these instructions give the basic connection method for a single flowmeter system.

Refer to the illustration that follows during the installation procedure.

Some of these parts may be located on the engine. 1. Diesel fuel tank. 2. Primary filter. 3. Caterpillar Supply Fuel Flowmeter Group. 4. Fuel transfer pump. 5. Fuel filter. 6. Fuel supply line. 7. Fuel injection pump.

This illustration shows the fuel flowmeter group installed in the best location in the engine fuel supply line.

It is between the primary fuel filter and the fuel transfer pump. Other locations are discussed in the procedure that follows.

1. Compare the fuel system diagram shown, to the actual fuel system on the engine to be tested.

Note the location of the fuel supply line and check to see if there is clearance and easy access to permit installation of the flowmeter group

The flowmeter group is installed with hoses to connect into the fuel line with the flowmeter located at the end of the hoses.

If the location for the supply flowmeter is not accessible, it can be installed in an alternate location as follows:

NOTE: Two types of fuel transfer pumps are used on Caterpillar engines. These are identified as gear type and piston type.

Refer to Identification of Fuel Transfer Pump, in this manual, to identify the type of fuel transfer pump on the engine to be tested.

* If the engine has a gear type fuel transfer pump, the flowmeter can be installed in the line between its output and the secondary fuel filter.

NOTE: Do not install the flowmeter after the output of a piston type fuel transfer pump. The pulsations from a piston type fuel transfer pump will cause inaccurate fuel readings.

* On engines that have a gear type fuel transfer pump, the flowmeter may also be installed between the fuel filter and the fuel injection pump.

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NOTICE
Extreme care must be taken to not contaminate the fuel injection pump during installation and removal, or damage to the pump may result.

2. Refer to Two Flowmeter (Supply & Return) Installation Instructions, in this manual, and follow Steps 2 through 9 for the supply flowmeter only.

Identification of Fuel Transfer Pump

There are two basic types of fuel transfer pumps used on Caterpillar diesel engines:

* Gear Type Pump ... and

* Piston Type Pump

The type of fuel transfer pump being used MUST be identified, if a Caterpillar fuel flowmeter is to be installed after the outlet of the pump.

The reason for this is that the pulsations from a piston type pump will give incorrect flow rate readings.

The following information gives examples of both types of fuel transfer pumps.

Gear Type Fuel Transfer Pump

Gear type fuel transfer pump.

A GEAR TYPE transfer pump is shown above.

All early model Caterpillar engines have a GEAR TYPE fuel transfer pump.

It can easily be identified because it is larger, and its shape is more square than a PISTON TYPE fuel transfer pump.

Its input and output lines are located on opposite sides of the pump body.

With this type of fuel transfer pump, the flowmeters can be located on either the INPUT or OUTPUT line. This is because the output fuel flow is continuous and does not pulsate.

Piston Type Fuel Transfer Pump

The 3204, 3304, 3306 and 3406 Family of engines with the NEW SCROLL fuel system have a PISTON TYPE fuel transfer pump (1) as shown.

The PISTON TYPE pump is smaller and has more rounded areas on it than a GEAR TYPE fuel transfer pump. The inlet fuel line for a PISTON TYPE pump always flows into the large round end of the pump (2).

Sometimes, however, the pump end cap is changed to make the inlet fuel line come from the side (3).

Outlet fuel line (4) always comes directly from the side.

If you are unsure which fuel line is the outlet fuel line, first locate the fuel line that leads to the engine fuel injection pump.

On engines with the PISTON TYPE fuel transfer pump:

* Install the fuel flowmeters on the INLET FUEL LINE ONLY.

If the connections are NOT made correctly, incorrect readings will result because of the pulsations the pump puts in the fuel stream.

Using the 8T9300 Fuel Flow Monitor

NOTE: Refer to the Setting the Monitor Turn On Select Switches in this manual, to change the functions that appear when the monitor is first powered up.

Before using the fuel flow monitor, refer to the following in this manual.

* Controls and Indicators on the Monitor.

* Powering the Fuel Flow Monitor System.

When using the fuel flow monitor, a code may appear on the display, instead of a value.

These codes may also appear when the flowmeter is first powered up, but, they will disappear if the flowmeter is working correctly. It takes eight seconds after correcting a problem, before the code will disappear. Each code and its description follows.

General Codes

UUUU = Flowmeter disconnected:

Meter is not connected to monitor or a wire is broken.

---- = Bad Data:

Indicates the flowmeter could not calculate good data.

Cause may be a malfunction of the flowmeter:

* Disconnect the power to the monitor power supply ... and

* Again apply power to the monitor power supply.

This may correct the problem.

UFL = Underflow:

The fuel flow being measured is lower than the minimum specification of the flowmeter.

OFL = Overflow:

The fuel flow being measured is higher than the maximum specification of the flowmeter.

Burn Total & Burn Average Display Codes

OFL = Flashing OFL, then a number, on the AVG or TOTAL display indicates the internal memory has an overflow.

When this happens, the total number flashing will be the new TOTAL starting over at zero and will be accurate. The AVG number flashing may not be accurate.

Err = BURN TOTAL & AVG error:

Flashing Err then a number on the TOTAL & AVG displays, indicates there has been an error that will cause these numbers to be inaccurate.

If this happens, the total will stop accumulating and the number shown will be the last good number recorded before the error.

The time the error occurred can be determined by dividing the TOTAL number by the AVG number. This will give the total number of hours of good operation data.

UFL = Flashing UFL, then a number, on the AVG or TOTAL display indicates a (-) negative value in the memory.

Refer to Negative Flow Rate Readings in this manual for more information.

Two Flowmeter System Codes

When the monitor is set up for a two flowmeter system (Supply Flowmeter and Return Flowmeter), the display will flash to indicate a problem on either flowmeter, even if it is not being monitored at that time.

The information for the flowmeter being monitored will appear on the display, and then the problem code for the other flowmeter will appear on the display to indicate a problem.

For each display, the SUPPLY or RETURN arrow will indicate for which flowmeter or flowmeters the information is being shown.

Example:

The supply rate is being viewed and the return flowmeter flow is below the minimum rating of the flowmeter.

First, the supply rate will be displayed and the SUPPLY arrow will be ON.

Next, the UFL code will appear and, at the same time, the RETURN arrow will be ON.

This sequence will continue until the return flow is increased above the minimum.

Steps For Measuring Fuel Flow

1. Connect power to the monitor.

Refer to Connecting the Power Supply to the Monitor in this manual.

Connect the flowmeter(s) as described in the specific installation instructions.

After power is connected to the indicator power supply, the display will require 30 seconds for a good reading to appear.

Also, if a flowmeter cable is disconnected for any reason, it requires 30 seconds after the cable is connected, for a good reading to reappear.

2. Check the display to be sure there is no arrow above the DISPLAY HOLD label.

If an arrow is present, press the HOLD/CLEAR switch to remove the arrow and allow the display to be updated.

3. Select one flowmeter (SUPPLY), or two flowmeter (SUPPLY & RETURN) on the monitor, so the indicator arrow at the bottom of the display points to the correct label.

To change the selection:

* Press the METER SELECT switch and at the SAME time ...

* Press the SUPPLY/S&R switch.

The indicator arrow will move on the display to indicate the selection.

NOTE: Two switches are used for this function so the setting cannot be accidently changed.

If the single flowmeter mode of operation has been selected (SUPPLY) only, the display will not change if either the RETURN TEMP or the RETURN RATE switch is pressed.

4. Read the temperature of the fuel in the supply flowmeter by pressing either SUPPLY TEMP or RETURN TEMP (two flowmeter operation only) buttons.

The fuel temperature will appear on the display, followed by a C (for centigrade), or a F (for Fahrenheit).

To change from C to F, or F to C, press the C/F switch. The temperature will register even if the engine is not operating.

5. After the engine is operating, fuel flow in the supply and return flowmeters can be observed.

Press either the SUPPLY RATE or the RETURN RATE switch.

Fuel flow for the line selected will show on the display. An arrow on the display will indicate either LPH (liters per hour) or GPH (gallons per hour).

To change from liters to gallons, or gallons to liters, press the LIT/GAL switch.

If the flow through the flowmeter selected is below, or above, the rating of the flowmeter that is connected, the display will indicate either UFL or OFL.

6. Press the BURN RATE button to read engine fuel consumption.

7. Press the BURN TOTAL button and the amount of fuel burned since the start of the test will be shown on the display.

To reset this number to 0 (zero), and restart the count:

* Press and hold the BURN TOTAL button and at the SAME time ...

* Press the HOLD/CLEAR button.

8. To read the average burn rate since the start of the test, press the BURN AVG button.

To start a new average reading:

* Press and hold the BURN AVG button and at the SAME time ...

* Press the HOLD/CLEAR button.

NOTE: If a long term BURN TOTAL or BURN AVERAGE test is being performed, the memories could be filled to overflow, and the information will be lost.

To prevent this from happening, refer to the specifications for the length of time required to fill the memories.

Record the fuel data before the memories fill, then reset the memories to 0 (zero) and start over.

Negative Flow Rate Reading

When one flowmeter operation (SUPPLY) is being used, there is no indication for negative flow (flow through the flowmeter in the direction opposite the arrow).

Any reverse flow through the flowmeter will display on the monitor as a positive flow.

Negative flows are shown when a two flowmeter operation (SUPPLY & RETURN) is being used.

The monitor will indicate negative flow rates with a minus (-) sign on the BURN RATE display.

This will happen if the supply and return flowmeter cables are reversed, or, if the actual supply flow is less than the return flow.

This can happen for short periods of time on some engines, when the governor quickly shuts off fuel to the engine.

If a negative flow rate is measured, that amount will be subtracted from the TOTAL BURN number in memory and the AVG number will also decrease.

If the TOTAL BURN and AVG BURN numbers become less than 0 (zero) (negative number), this is indicated on the display by a flashing UFL.

The number that is flashing on the TOTAL display:

* Will be equal to the negative total value subtracted from 20,000.

The number that is flashing on the AVG display:

* Will be near 0 (zero) and not meaningful.

If the TOTAL number goes back to positive after being negative:

* OFL will flash on the display.

This can be removed by clearing the AVG and TOTAL.

Interpretation and Conversion of Test Results

The Caterpillar Fuel Flow Monitor System measures and displays fuel information in units of Liters or U.S. Gallons, with the volume corrected to 15.6° C (Centigrade), or 60° F (Fahrenheit).

This correction is automatically accomplished in the flowmeters.

It may be desirable to convert this fuel volume information into other units of measurement, such as fuel mass (fuel weight). An explanation of this conversion follows.

The fuel flowmeters are calibrated to measure fuel volume with an API density of 35°. The fuel being used, however, may not be at this density.

To convert the fuel volume units, such as fuel mass, fuel density must be known.

There are two thermo-hydrometers and a beaker available for measuring fuel density. These are shown in Optional Items for Use with the Fuel Flow Monitor Group in this manual. They are needed to determine the fuel density for conversion to other units of measure.

Special Instruction ... SMHS9224, Measuring API Gravity is also needed, and is supplied with the thermo-hydrometers.

To Convert to Fuel Weight

Use the procedure as shown in Special Instruction ... SMHS9224, Measuring API Gravity to:

* Measure the API gravity and temperature of the diesel fuel.

* Determine the corrected API gravity number from the chart.

To do this, find the measured fuel temperature in the left column of the chart.

From that temperature, move to the right on the chart, to the vertical column that has the measured API gravity number at the top.

Record the corrected API gravity number from inside the box where the two columns cross each other.

* Refer to the chart, on the back page of the instruction, to convert the API Gravity to either kg/liter or lbs./U.S. Gallon specific fuel weight.

Multiply the specific fuel weight by the number of liters or lph, or U.S. Gallons or gph of fuel burned.

Example:

The diesel fuel measures 37° API and 90°F temperature using the 1P7408 Thermo-hydrometer. The chart in the instruction gives a corrected API gravity of 35.

The chart at the back of the instruction shows the fuel has a weight of 7.076 pounds per U.S. Gallon.

The fuel meter shows 18 U.S. Gallons were burned during the test. This is 18 X 7.076, or 127.368 pounds of diesel fuel burned.

Brake Specific Fuel Consumption (BSFC) or Corrected Specific Fuel Consumption (CSFC)

Once the fuel density is obtained, the calculated horsepower of the engine may be found by, dividing the fuel weight by the Brake Specific Fuel Consumption (BSFC)¹, or Corrected Specific Fuel Consumption (CSFC)² of the engine.

---

¹This value (term) is for engines built before approximately 12-83.

The microfiche libraries SBFY1106 - (12/83) ... Current Vehicular Engines and SBFY1107 - (12/83) ... Current Gas, On Highway Truck and Agricultural Engines use the term Brake Specific Fuel Consumption (BSFC).

---

²This value (term) is for engines built after approximately 12-83.

The following microfiche libraries use the term Corrected Specific Fuel Consumption (CSFC).

The SBFY1108 ... Fuel Setting and Related Information microfiche libraries (include):

* SBFY1109 ... Vehicle (Captive) Engine Fuel Specifications:

Captive engines only.

Use the Industrial Engine Fuel Specifications library for O.E.M. manufactured off-highway trucks using a Caterpillar engine.

* SBFY1110 ... Industrial Engine Fuel Specifications:

Industrial applications, marine generator sets and Caterpillar engines used in O.E.M. manufactured off-highway trucks.

Use the Truck Engine Fuel Specifications library for Caterpillar on-highway truck engines.

* SBFY1111 ... Marine Engine Fuel Specifications:

Propulsion only.

Use the Industrial Engine Fuel Specifications library for information on power generation in marine applications.

* SBFY1112 ... Agricultural Engine Fuel Specifications:

O.E.M. manufactured agricultural machines using a Caterpillar engine.

Use the Vehicle (Captive) Engine Fuel Specifications library for information on track type S.A. vehicles and the Challenger 65 and 75.

* SBFY1113 ... Truck Engine Fuel Specifications:

Caterpillar on-highway truck engines.

Use the Industrial library for information on Caterpillar engines used in O.E.M. manufactured off-highway trucks.

The BSFC or CSFC for the engine arrangement being measured can be found in the appropriate Fuel Setting or Fuel Setting and Related Information microfiche library.

Additional Operating Instructions

Aeration

The aeration can be observed in the sight glass but is difficult to remove.

Some engines, the 3100 Family and slow speed rated 3500 Family engines, may require different methods and/or equipment to reduce aeration:

* Install a 3/4 inch gate valve AFTER the return meter to restrict the return line.

* Open the gate valve.

* START engine and close the gate valve until a maximum of 80 psi fuel pressure is reached.

As the gate valve is closed the aeration, with a light behind the sight glass should be visibly reduced.

An alternate method is to:

* Install a 20 psi pressure relief check valve AFTER the return flowmeter.

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NOTICE
Do NOT completely shut OFF the engine return fuel flow. Monitor the fuel system pressure BEFORE the restriction so that it does NOT exceed 80 psi. Failure to do so may cause engine damage.

If these methods and/or equipment does not reduce aeration to an acceptable level a De-Aerator Tank and De-Aerator Group may be required.

Refer to NEHG3563 (1/90) ... Tool Announcement

The Tool Announcement gives a complete description of the De-Aerator Group and De-Aerator Tank operation with Caterpillar engines and competitive engines.

The De-Aerator Group and De-Aerator Tank are fabricated tooling and the FT drawings are available from the factory.

Fuel Flow Monitor System Troubleshooting Chart

Checking the Operation of the Fuel Flow Monitor System

Use the following procedure to check the operation of the entire Fuel Flow Monitor System.

NOTE: This procedure is intended to be a function check ONLY, to see if everything is functioning. It is NOT an accuracy check.

The only components required for this procedure are one of the fuel flow monitor arrangements or a 4C9764 Fuel Flow Monitor Group, and at least one fuel flowmeter. Do the steps that follow to perform the test.

1. Connect power to the Fuel Flow Monitor.

Refer to (in this manual):

* Powering the Fuel Flow Monitor System

* Connecting the 8T9280 Power Supply to the Monitor .. and/or

* AC Power Operation Using 8T9276 Optional AC Power Supply

2. After power has been applied to the monitor power supply, activate the POWER ON switch.

The indicator should turn ON and an indication should appear on the monitor display.

3. Look at the bottom of the digital display. If an arrow points to DISPLAY HOLD, press the HOLD/CLEAR switch until the arrow disappears.

Single Flowmeter Tests

1. Use a 1U5298 Cable to connect a fuel flowmeter to the SUPPLY METER connector on the monitor.

Press the METER SELECT switch and at the SAME time press the SUPPLY/S&R switch, to move the arrow between SUPPLY METER and SUPPLY & RETURN METERS.

After pressing the switches, if the arrow does not point to SUPPLY METER, press both switches again to move the arrow.

5. Press the SUPPLY TEMP switch. If the flowmeter has been connected for at least 30 seconds, the temperature of the flowmeter will show on the display.

This temperature should show the temperature of the flowmeter. This temperature reading will gradually rise from self heating if no fuel is flowing through the flowmeter to cool it.

An arrow should point to SUPPLY on the left side of the display.

A letter C (Centigrade) or F (Fahrenheit) will show following the number on the display.

Press the C/F switch and the display temperature should change to the corresponding value in degrees C or F.

3. Press the RETURN TEMP switch and the display should not change.

4. Press the SUPPLY RATE switch and the display should read UFL for underflow.

Press the LIT/GAL switch.

The arrow at the right of the display should alternate between LPH and GPH each time the switch is pressed.

If the flowmeter is now installed in a known fuel flow line that is within the range of the flowmeter, it should read the correct flow rate.

If it is not possible to install the flowmeter in a known fuel flow line, it is possible, but rather difficult, to get a flow reading on the monitor by blowing your breath through the flowmeter as a function check.

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NOTICE
Do not use unregulated pressure air to blow through the flowmeter, or damage to the flowmeter bearings may result.

Getting a flow reading by blowing your breath through the flowmeter is very difficult.

The turbine inside the flowmeter must be made to spin at a speed that is within the flow range of the flowmeter for a period of 15 seconds.

Only then will any value appear on the display.

If the turbine spins too fast or too slow, no reading will appear.

With practice, however, this method can be used to test the flowmeters.

This test is much easier on the large flowmeters than it is on the small flowmeters. This is because the turbine wheel can be seen easier and will spin for a longer period of time.

5. To perform this test:

* Remove the end caps from the flowmeter and spray some 1U5499 Lubricant into the flowmeter turbine, so the bearings will not be operated dry.

* Point one end of the flowmeter toward a light, or a light colored surface.

First, look through the bore of the flowmeter, and then blow through it lightly.

You should be able to see the turbine spin and then come to a stop after a short period of time.

When the turbine spins it will make a soft whining noise. This noise can be used as a guide to tell how fast the turbine is spinning.

If the pitch of the turbine gets to high, you are blowing too hard.

6. If the turbine does not spin, the flowmeter may need cleaning.

Refer to Care and Maintenance of the Fuel Flowmeter Groups, in this manual, for cleaning information.

By blowing through the flowmeter continuously for 15 seconds, just hard enough to keep the turbine spinning, it is possible to get a reading on the monitor that will indicate if the flowmeter is operating.

This is ONLY a function check, however, and an actual fuel flow test is the only way to check the accuracy of the flowmeter.

7. After all tests are completed, spray 1U5499 Lubricant (or equivalent) into the flowmeter turbine, then install the end caps on the flowmeter group.

8. The OFL (overflow warning) can be checked by blowing in the flowmeter with the monitor reading supply rate as in the previous step, and then blowing harder into the flowmeter until the display reads OFL.

Before OFL will appear, a flow value within the correct range of the flowmeter must be present on the display.

9. Press the RETURN RATE switch and the display should not change.

10. To check the DISPLAY HOLD function:

* Press the SUPPLY TEMP switch.

The display should show the flowmeter temperature.

* Press the HOLD/CLEAR switch and an arrow should appear above DISPLAY HOLD and then ..

* Press the SUPPLY RATE switch.

Nothing should change on the display.

* Press the HOLD/CLEAR switch and the arrow above DISPLAY HOLD should disappear.

11. To test the burn rate function with a supply flowmeter only connected:

* Press the BURN RATE switch.

An arrow should appear at BURN RATE on the display, and the display will show UFL for underflow.

To show a burn rate value on the display, the flowmeter turbine must be made to spin as described in steps 4 through 7.

In the single flowmeter mode (which you are now in), the burn rate is the same as the supply rate reading.

12. To check the burn total:

* Press the BURN TOTAL switch.

If the turbine is not turning in the flowmeter, the display will alternate between the value stored in the burn total memory and UFL, to indicate the flowmeter is underflow.

Spinning the flowmeter turbine now, as described earlier, will make the display burn total value increase slowly.

This burn total number may be 0 (zero) if you did not get readings to appear by spinning the flowmeter turbine in the earlier steps.

If you were able to get readings to appear on the monitor, the burn total number will be greater than 0 (zero).

* Press the LIT/GAL switch and the number on the display should change from LITERS to GALLONS.

To clear the burn total memory, press:

* The HOLD/CLEAR switch and the BURN TOTAL switch at the SAME time.

After pressing both switches, the display should read .00.

If the DISPLAY HOLD arrow comes ON during this step and .00 does NOT appear:

* Press the HOLD/CLEAR switch and repeat the previous step if necessary.

13. Burn Average can be checked using the same procedure as in step 11, but, use the BURN AVG switch instead of the BURN TOTAL switch.

If your system has only one fuel flowmeter, this is the end of the test.

The previous 12 steps can be used over at any time to check another flowmeter, if all the tests were successful.

If your system has two flowmeters, continue with the steps that follow.

Two Flowmeter (Supply & Return) Tests

1. With a flowmeter connected to the SUPPLY METER connector from the previous tests, connect a second flowmeter to the RETURN METER connector.

Press the METER SELECT and SUPPLY/S&R switches at the SAME time:

* To move the arrow at the bottom of the display to SUPPLY & RETURN METERS.

This puts the monitor in the two flowmeter mode of operation.

2. Press the SUPPLY TEMP switch:

* The supply flowmeter temperature should show on the display whenever an arrow points to SUPPLY, then alternate to UFL when the arrow moves to RETURN.

This is for a warning that the return flowmeter is underflow.

3. Press the RETURN TEMP switch:

* The return flowmeter temperature should show on the display, alternating with the SUPPLY flowmeter UFL warning.

4. Press the SUPPLY RATE switch:

* The SUPPLY and RETURN arrows will both be ON.

The display will show UFL if the flowmeter turbine is not spinning at the correct speed.

If the supply flowmeter turbine is made to spin as described earlier, the flow value will appear on the display, alternating with UFL for the return flowmeter underflow warning.

5. Press the RETURN RATE switch:

* The SUPPLY and RETURN arrows will both be ON.

The display will show UFL if the flowmeter turbine is not spinning at the correct speed.

If the return flowmeter turbine is made to spin as described earlier, the flow value will appear on the display, alternating with UFL for the supply flowmeter underflow warning.

6. Press the BURN RATE switch:

* Arrows should appear at RATE-BURN, SUPPLY, and RETURN on the display, along with UFL if either flowmeter is underflow.

To get a burn rate reading to appear, both flowmeter turbines must be made to spin at the correct speed. This is very difficult to do by blowing into the flowmeters and is not recommended.

If a test is desired, connect both flowmeters in series in a known fuel flow that is above the flowmeter minimum flow. Since both flowmeters are reading the same flow rate, the supply rate and the return rate should be approximately the same.

The burn rate will be approximately 0 (zero). The readings will NOT be exact, because the second flowmeter in the line will be influenced by the disturbed flow through the previous flowmeter.

It does, however, provide a functional check.

7. In the two flowmeter mode, the BURN TOTAL and BURN AVG functions work basically the same as in the single flowmeter mode:

8. To test the burn rate function with a supply flowmeter only connected:

* Press the BURN RATE switch.

An arrow should appear at BURN RATE on the display, and the display will show UFL for underflow.

To show a burn rate value on the display, the flowmeter turbine must be made to spin as described in steps 4 through 7.

In the single flowmeter mode (which you are now in), the burn rate is the same as the supply rate reading.

9. To check the burn total:

* Press the BURN TOTAL switch.

If the turbine is not turning in the flowmeter, the display will alternate between the value stored in the burn total memory and UFL, to indicate the flowmeter is underflow.

Spinning the flowmeter turbine now, as described earlier, will make the display burn total value increase slowly.

This burn total number may be 0 (zero) if you did not get readings to appear by spinning the flowmeter turbine in the earlier steps.

If you were able to get readings to appear on the monitor, the burn total number will be greater than 0 (zero).

* Press the LIT/GAL switch and the number on the display should change from LITERS to GALLONS.

To clear the burn total memory, press:

* The HOLD/CLEAR switch and the BURN TOTAL switch at the SAME time.

After pressing both switches, the display should read .00.

If the DISPLAY HOLD arrow comes ON during this step and .00 does NOT appear:

* Press the HOLD/CLEAR switch and repeat the previous step if necessary.

10. This completes the check of the fuel flow monitor system. Be sure to spray 1U5499 Lubricant, or its equivalent, into the flowmeters. Install the end caps on the flowmeters.

Care and Maintenance of the Fuel Flowmeter Groups

To maintain accuracy, of the supply and return fuel flowmeter groups, cleaning and maintenance of the meters must be done correctly each time a test is completed and the flowmeters are taken off the engine.

If the following procedures are adhered to, it will help to keep the meters operating properly:

* Always keep the end caps installed on the flowmeters when the flowmeters are not being used.

* DO NOT apply pressure air through the flowmeters, or damage to the turbine bearings may result.

* DO NOT drop the flowmeters, or strike the sight glass. Damage may result.

* DO NOT over tighten the fittings on the ends of the sight glass or they will be damaged and crack.

* When the flowmeters are not installed on an engine, they should be kept filled with diesel fuel or cleaned.

* Use an approved cleaning solution as described in Cleaning the Flowmeter Groups in this manual.

* NEVER permit dirt or contamination to enter the flowmeters.

Cleaning the Flowmeter Groups

The following notice appears on the fuel flowmeter case.

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NOTICE
To prevent sticking of meter turbine, keep full of diesel fuel, or clean with approved solvent after use.

Use the Caterpillar 1U5499 Lubricant to clean the meters.

If this lubricant is not available, or is not successful, contact the Caterpillar Service Technology Group for any additional, approved cleaning solvents.

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NOTICE
If an unapproved solvent is used to clean the meters, the sight glass may become cloudy or brittle, and crack. This will cause fuel to leak when the meter is in use.

1. To clean the meters:

* Remove the end cap (pipe cap) from one end of the meter assembly.

* Spray or pour the cleaning solvent into the meter.

* Fill the chamber inside the meter assembly approximately 1/3 full of the cleaning solution.

2. Install a cap on the open end of the meter:

* Shake the meter back and forth so the cleaning solution runs from one end to the other, and past the meter turbine.

3. Remove an end cap from the meter and:

* Pour out the cleaning solution.

4. Remove the remaining end cap. With both caps removed:

* Examine the meter carefully by looking down the bore for debris or any other kind of contamination.

* Repeat the cleaning process if necessary.

After the meter is clean, gently blow through the meter with your breath to see if the turbine spins.

NOTE: Do not blow compressed air through the meter or the turbine bearings may be damaged.

5. If the turbine spins freely and continues to spin for a short time after blowing through the meter, the meter can be considered as being clean.

After cleaning is complete:

* Spray a small amount of 1U5499 Lubricant (or equivalent) on the turbine bearings to lubricate them.

* Install the end caps.

6. If the turbine does not spin when blowing through the meter, the turbine is stuck.

This happens when diesel fuel has been allowed to dry inside the meter.

The residue from the dried diesel fuel causes a varnish to form inside the bearings. This varnish prevents the bearings from turning.

To remove varnish from the bearings:

* Spray 1U5499 Lubricant, or other approved cleaning solvent, on the turbine bearings ... or

* Put a cleaning solution inside the meter and let it sit for a period of time, to soak the turbine bearings and remove the varnish.

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NOTICE
Do not permit the cleaning solution to enter the sight glass when soaking the meters. The sight glass may become discolored. Stand the meter assembly on end with the sight glass on top, then fill the meter only, with the cleaning solution.

7. After soaking, repeat Steps 1 through 5 to check and prepare the meter for storage. If the turbine is still stuck, repeat this procedure until the turbine turns freely.

8. Always spray the meter turbine with 1U5499 Lubricant, or other approved solvent, then replace both end caps before storing the meter.

Checking the Accumulator on the Flowmeter Groups

The 1U5295 Accumulator, mounted on the fuel flowmeter groups, works as a pulse dampener to remove pressure pulses that may be present in the engine fuel lines.

Inside the accumulator is a special bladder that is resistant to diesel fuel.

This bladder should have no pressure or vacuum in it when the flowmeters are not installed.

If the pressure in the accumulator is not correct, the flowmeters may give inaccurate readings.

Although there is no pressure in the bladder, it should have the pressure relieved to test it and give it the proper charge.

This should be done at least once every 12 months.

1. Remove screw (1) from the end of the accumulator.

2. With a small screwdriver, press the valve stem in the end of the accumulator to relieve all pressure.

3. Replace screw (1).

Setting the Monitor Turn-ON Select Switches

It is desirable to have the 8T9300 Monitor ready to read after power is applied.

Three switches inside the monitor can be used to automatically select either one or two meter operation, every time power is applied to the monitor.

Fuel temperature will be displayed in either Centigrade or Fahrenheit and fuel information will be displayed in either Liters or Gallons.

Once these switches are set, the monitor will always be in the selected operational mode when power is applied.

Use the following procedure to set the switches.

1. Disconnect all cables from the monitor. Remove the rear cover from the monitor.

2. Locate the small square block that has three slide switches (1). This block is located in the lower right corner of the top printed circuit board.

To change the operational mode, move the small sliders to the desired letter that represents the functions. The letters are located next to the switch on the printed circuit board.

3. Use the top switch (the one closest to the connector panel) to select L for Liters, or G for Gallons

4. Use the center switch to select °C for Centigrade, or °F for Fahrenheit for fuel temperature.

5. Use the bottom switch (one nearest the edge of the printed circuit board) to select 2M for two meter operation, or 1M for one meter operation.

6. After moving the switches to the desired positions, install the rear cover on the monitor.

Fuel Filter Housing Identification (Early Model D300 Family Engines)

Some early model D300 Engines have a fuel filter housing with a fuel flow rate of more than 265 lph (70 gph).

This will make it necessary to either use the 1U5440 Flow Monitor Arrangement, or block the return flow and use only the 4C9758 Supply Meter.

The illustrations that follow show two types of fuel filter housings, for identification purposes.

Cast fuel filter housing.

Fabricated fuel filter housing.

Individual Replacement Parts List for Flowmeter Groups

Service Parts for 4C9758 Supply Fuel Flowmeter Group (Small)

NOTE: The former part number was 1U5301

Service Parts for 4C9759 Return Fuel Flowmeter Group (Small)

Service Parts for 4C9760 Supply Fuel Flowmeter Group (Large)

Service Parts for 4C9761 Return Fuel Flowmeter Group (Large)

Repair of the Caterpillar Fuel Flow Monitor System

If the fuel flow monitor system does not operate correctly:

* Refer to Fuel Flow Monitor System Troubleshooting Chart

If the problem still cannot be located, disconnect the system from the engine and:

* Refer to Checking the Operation of the Fuel Flow Monitor System in this manual.

* Try to isolate the problem to one item such as the meter.

* First try one meter, then the other meter, in the supply connector on the monitor.

If the system does not work correctly, contact the Caterpillar Service Technology Group for information on how to obtain the needed repair service.

Use the address or one of the telephone numbers that follow, to contact the Caterpillar Service Technology Group if you encounter difficulty in the repair of this tool.

U.S. Mail:

Caterpillar Service Technology Group
LD180
Attn: Product Support Manager
600 West Washington Street
East Peoria, IL 61630-0253

Telephone:

1-800-541-8665 (Inside Illinois)

1-800-542-8665 (Outside Illinois)

1-800-523-8665 (Canada)

Outside of North America use Telex #404435

If the tool, or any part of it, is to be sent to Caterpillar for repair, be sure to first contact Caterpillar Service Technology Group as indicated.

Before sending the tool, to one of the addresses below, be sure to enclose a letter that describes the problem, and give the date of purchase from Caterpillar. Tools that are less than one year old will be repaired under warranty (except for abuse). The cost for out of warranty repair will be charged to the owner.

Mailing addresses are as follows:

U.S. Mail:

Caterpillar Service Technology Group
LD180
Attn: Product Support Manager
600 West Washington St.
East Peoria, IL 61630-0253

UPS and EMERY only:

Caterpillar Service Technology Group
Attn: Product Support Manager
330 S.W. Adams St.
Peoria, IL 61602