Small Engine Fuel Systems - Wanderlodge Owners Group
Engine Service TrainingLEGV4801-02Instructor Course BookSeptember 2002ENGINE COURSE BOOKSmall Engine FuelSystemsSMALL ENGINE FUEL SYSTEMS
LEGV4801-02Course Description-29/02COURSE DESCRIPTIONSmall Engine Fuel SystemsContent4 1/2 Days2050NoneThis course is an in-depth study of the Caterpillar fuel systems for the3114, 3116, 3126/3126B/E, C-9 and 3208 engines. Participants willlearn to test and adjust the 1.1 and 1.2 liter mechanical and HEUI fuelsystems and the sleeve metering fuel system used on the 3208 engines.Caterpillar fuel injection pumps, governors, unit injectors, and nozzleswill be studied.AudienceReferences Explain the relationship of horsepower, rack, boost, fuel rate, torqueand BSFC Explain the engine operating tolerances and the relationship ofdensity of fuel and air to engine performance Explain the operating principles of the mechanical unit injectors,HEUI fuel systems and sleeve metering fuel systems. Demonstrate the adjustments of 1.1 liter and 3208 governors. Demonstrate the removal and installation of a 1.2 liter HEUIinjector and Injector sleeve. Test 7000 series, capsule and pencil nozzles. Check and adjust fuel settings. Check and adjust unit injector synchronization and timing. Explain the operation of the C-9 fuel systemStudents attending this course must be able to use the service manualand Caterpillar fuel system tools. Participants must also have a basicknowledge of diesel engine systems. Priority will be given toindividuals designated by dealerships to become a Certified EngineInstructor.Students attending will be asked to bring approved safety glasses andwear only rigid style shoes. (No canvas tennis shoes or open toe shoes).Students should also bring a calculator.
LEGV4801-02-3-Slide/Text Reference9/02Small Engine Fuel SystemsScheduleDayMondaySec. Subject1 Introduction and Pre-Test8:009:002 Fuel Selection9:009:30Break9:309:45Fuel Selection9:4510:3010:3011:0011:0011:453 Fuel Related Problems11:4512:154 Basic Governor Theory12:1512:305 Performance Curves12:302:302:302:456 Horsepower Correction Factors2:454:007 Quiz 18:008:308 Fuel Setting h11:3012:15Injector Adjustment Lab12:152:30Break2:302:45Injector Adjustment Lab2:453:0011 Governor Disassembly & Assembly3:004:00Governor Disassembly & Assembly8:009:009:009:303 Fuel Related ProblemsLunchBreakTuesdayBreak9 1.1/1.2 MUI Fuel System Introduction10 Injector Adjustment LabWednesdayTime12 Quiz 2
LEGV4801-02-4-Slide/Text Governor Test Stand Lab12:1512:4512:452:302:302:4515 Introduction to 1.1/1.2 HEUI Fuel Systems2:454:00Introduction to 1.1/1.2 HEUI Fuel 12:001:0019 3208 Lab1:002:30Break2:302:4519 Intro to Fuel Lines & Nozzles2:454:00Intro to Fuel Lines & 13 Governor Test Stand Lab14 1.1/1.2 Injector Sleeve LabBreakThursday16 Quiz 3Break17 Introduction to C-9 HEUI Fuel SystemLunch18 Introduction to 3208 Fuel SystemFriday20 Nozzle Test LabBreak20 Nozzle Test Lab23 Final and Course Evaluation
LEGV4801-02-5-Literature List9/02Small Engine Fuel SystemsLiterature ListRegistration FormCopySmall Engine Fuel System ScheduleCopyGlossary of TermsLEXQ9297Pre-TestCopyFuel Selection Slide ScriptCopyDiesel Fuel and Your EngineSEBD0717Engine Performance ReferenceLEXT1044Blending Used Crankcase OilLEKQ6070Blending Used Crankcase Oil for use with Cat HD Diesel EnginesLEKQ6071Basic Governor Theory Slide ScriptCopyPower Curve Slide ScriptCopyTest Condition Slide ScriptCopySample 0T/2T Information from the TMI/SIS or SIS WebCopySample Engine Performance Information from the TMI on-line systemCopyQuiz 1Copy1.1 Liter Fuel System Slide ScriptCopySystems Operation T & A, 3114, 3116, 3126 EnginesSENR3583Torque SpecificationsSENR3130Using the 128-8822 Tool Group on 3114, 3116, & 3126 EnginesHEHS0610Service Manual, 3114, 3116, 3126 Engine GovernorSENR6454Quiz 2Using the 143-2099 Sleeve Replacement Tool GroupCopyNEHS06751.1 and 1.2 HEUI Fuel System Slide ScriptCopyQuiz 3CopyC-9 Fuel System Slide ScriptCopyHEUI HI300B Fuel SystemRENR1392
LEGV4801-02-6-Literature List9/026V4141 Sleeve Calibration ToolSMHS 78355P6577 Fuel Setting Tool GroupSMHS7013Analyzing Fuel Nozzle and Fuel Line FailuresSEBD0639Using the 5P4150 Nozzle Testing GroupSEHS7292Test Sequence for Capsule Type Fuel NozzlesSEHS7350Test Sequence for 7000 Series Fuel NozzlesSEHS9083Test Sequence for Pencil-Type Fuel NozzlesSEHS7390Final TestCopyCourse Evaluation SheetCopy
LEGV4801-02-7-Literature List9/02Small Engine Fuel SystemsStudent Literature ListRegistration FormCopySmall Engine Fuel System ScheduleCopyPre-TestCopyEngine Performance ReferenceLEXT1044Sample 0T/2T Information from the TMI/SIS or SIS WebCopySample Engine Performance Information from the TMI on-line systemCopyQuiz 1CopyQuiz 2CopyQuiz 3CopyFinal TestCopyCourse Evaluation SheetCopy
LEGV4801-02-8-9/02Small Engine Fuel SystemsHardware ListSlide ProjectorScreenFuel Selection Slides1P7408 Thermo-hydrometer5P2712 Thermo-hydrometer1P7438 BeakersVarious fuel samplesBasic Governor SlidesPower Curve SlidesCalculatorTest Conditions SlideOn-line Terminal1.1 Liter Fuel System Slides1.1 or 1.2 liter Mechanical Engine128-8822 Tool GroupHand Tools1.1 or 1.2 Mechanical Governor128-8822 1.1 Liter Engine Injector Tool Group1U7315 1.1 Liter Engine Governor Tool Group1U7326 Governor Calibration Bench1U9786 Calibration Pin1U6673 FRC Adjustment Wrench1U9893 Solenoid Spanner Wrinch6V6106 Dial Indicator1U8815 Contact PointLiterature List
LEGV4801-02-9-9/0215 psi Air Supply143-2099 Sleeve Replacement Tool Group1.1 and 1.2 HEUI Fuel System SlidesC-9 HEUI Fuel System SlidesHEUI HI300B CDPC Computer3208 Fuel System Slides3208 Engine with Pump and Governor6V4141 Sleeve Calibration Tool Group5P6577 Fuel Setting Tool Group5P4150 Nozzle Test GroupVarious Fuel NozzlesLiterature List
LEGV4801-02- 10 -Lesson Plan9/02Small Engine Fuel SystemsLesson Plan 1 - Introduction & Pre-testObjectives: The instructor will complete all administrative duties required for class start up. The instructor will explain the course objectives and course schedule to thestudents and answer any questions concerning them. The instructor will explain course safety procedures. The instructor will provide an introduction of himself, classmates and trainingfacility. The student will take a pre-test so the instructor can gain knowledge of theexperience level of the course participants so the instructor can select the proper levelto present the subject matter.Literature Needed:Registration FormCopySmall Engine Fuel System ScheduleCopyGlossary of TermsPre-TestHardware Needed:NoneTime Required:1 HourTasks Required by Instructor to Meet Objectives:1. Fill out registration forms.2. Introduce self and students.3. Explain course objectives, schedule, and safety procedures.4. Review how to use the Glossary of Terms.5. Administer and review pre-test with the students.LEXQ9297Copy
LEGV4801-02- 11 -9/02Small Engine Fuel SystemsLesson Plan 1 - Pre-TestSelect the best answer1. The spring force in a governor:A. Increases fuel rack hunting.B. Does not affect the fuel rack.C. Moves the fuel rack toward the fuel on position.D. Prevents rack movement.E. Moves the fuel rack toward the fuel off position.2. How can rated load rpm be increased?A. Increase the rack settingB. Increase high idleC. Increase fuel pressureD. Increase the torque setting3. If the A.P.I. of the fuel is lowered, the BTU content will go:A. UpB. DownC. Remain the same4. In the hydra-mechanical governor, oil pressure is used to:A. Compress the governor springB. Lubricate governor parts onlyC. Move the flyweightsD. Move the rackTest
LEGV4801-02- 12 -9/025. The governor flyweights:A. Prevents fuel rack movementB. Moves the rack toward the fuel off positionC. Moves the rack toward the fuel on positionD. Does not affect the fuel rack.6. The purpose of the fuel ratio control is to:A. Prevent turbocharger overspeedB. Limit maximum horsepowerC. Eliminate excessive smoke during accelerationD. To limit engine RPM until oil pressure builds up7. What is or causes black smoke?A. Unburned fuelB. Worn valve guidesC. OverfuelingD. Cracked cylinder liner8. What is or causes white smoke?A. Burning oilB. OverfuelingC. Incomplete combustionD. A and CE. None of the aboveTest
LEGV4801-02- 13 -9/029. Which of the following can cause excessive black smoke?A. Advanced timingB. High rack settingC. A and BD. None of the above10. Which of the following can cause a low power complaint?A. Using #2 diesel fuel instead of #1 diesel fuelB. Air inlet restriction of 15 inches of waterC. Exhaust back pressure of 10 inches of waterD. Mis-adjusted or bent accelerator linkage11. Which of the following can cause a low power complaint?A. Cloud point of the fuel too lowB. 37.2 API fuel and 90 degrees FC. Cetane of the fuel too highD. Increased altitude12. A gallon of diesel fuel has more B.T.U.'s than a gallon of gasoline.A. TrueB. False13. The best way to lower cloud point of a diesel fuel:A. Add alcoholB. Add gasolineC Add #1 dieselD Add cetaneE. All the aboveTest
LEGV4801-02- 14 -Test9/0214. A diesel fuel with a low cetane number can result in:A. Hard startingB. White smoke at startupC. Black smoke under loadD. Fuel filter pluggingE. A and BF. A and C15. The high idle adjustment can be made on the engine on a 3116 engine.A. TrueB. False16. The purpose of transfer pump pressure is:A. to increase engine horsepowerB. to disipate the water in the fuelC. to properly fill the plunger and barrel assembyD. to prevent filter plugging17. The horsepower tolerance for a Caterpillar engine with less than 100,000 miles is:A. 5%B. 3%C. 5% -3%D. 7% -5%18. As inlet fuel temperature increases:A. Maximum horsepower of the engine increasesB. Maximum horsepower of the engine decreasesC. Boost pressure increasesD. The fuel becomes more dense
LEGV4801-02- 15 -Test9/0219. It is recommended to use fuel heaters to overcome the effects of cold weather onfuels.A. TrueB. False20. Which of the 1.1 liter governor types use four governor flyweights to control rackmovement?A. Type 1B. Type 2C. Type 3D. Type 4E. Type 5
LEGV4801-02- 16 -Test9/02Small Engine Fuel SystemsLesson Plan 1 - Pre-Test MasterSelect the best answer1. The spring force in a governor:CA. Increases fuel rack hunting.B. Does not affect the fuel rack.C. Moves the fuel rack toward the fuel on position.D. Prevents rack movement.E. Moves the fuel rack toward the fuel off position.2. How can rated load rpm be increased?BA. Increase the rack settingB. Increase high idleC. Increase fuel pressureD. Increase the torque setting3. If the A.P.I. of the fuel is lowered, the BTU content will go:AA. UpB. DownC. Remain the same4. In the hydra-mechanical governor, oil pressure is used to:A. Compress the governor springB. Lubricate governor parts onlyC. Move the flyweightsD. Move the rackD
LEGV4801-02- 17 -Test9/025. The governor flyweights:BA. Prevents fuel rack movementB. Moves the rack toward the fuel off positionC. Moves the rack toward the fuel on positionD. Does not affect the fuel rack.6. The purpose of the fuel ratio control is to:CA. Prevent turbocharger overspeedB. Limit maximum horsepowerC. Eliminate excessive smoke during accelerationD. To limit engine RPM until oil pressure builds up7. What is or causes black smoke?CA. Unburned fuelB. Worn valve guidesC. OverfuelingD. Cracked cylinder liner8. What is or causes white smoke?A. Burning oilB. OverfuelingC. Incomplete combustionD. A and CE. None of the aboveE
LEGV4801-02- 18 -Test9/029. Which of the following can cause excessive black smoke?BA. Advanced timingB. High rack settingC. A and BD. None of the above10. Which of the following can cause a low power complaint?DA. Using #2 diesel fuel instead of #1 diesel fuelB. Air inlet restriction of 15 inches of waterC. Exhaust back pressure of 10 inches of waterD. Mis-adjusted or bent accelerator linkage11. Which of the following can cause a low power complaint?DA. Cloud point of the fuel too lowB. 37.2 API fuel and 90 degrees FC. Cetane of the fuel too highD. Increased altitude12. A gallon of diesel fuel has more B.T.U.'s than a gallon of gasoline.AA. TrueB. False13. The best way to lower cloud point of a diesel fuel:A. Add alcoholB. Add gasolineC Add #1 dieselD Add cetaneE. All the aboveC
LEGV4801-02- 19 -Test9/0214. A diesel fuel with a low cetane number can result in:EA. Hard startingB. White smoke at startupC. Black smoke under loadD. Fuel filter pluggingE. A and BF. A and C15. The high idle adjustment can be made on the engine on a 3116 engine.BA. TrueB. False16. The purpose of transfer pump pressure is:CA. to increase engine horsepowerB. to disipate the water in the fuelC. to properly fill the plunger and barrel assembyD. to prevent filter plugging17. The horsepower tolerance for a Caterpillar engine with less than 100,000 miles is:BA. 5%B. 3%C. 5% -3%D. 7% -5%
LEGV4801-02- 20 -Test9/0218. As inlet fuel temperature increases:BA. Maximum horsepower of the engine increasesB. Maximum horsepower of the engine decreasesC. Boost pressure increasesD. The fuel becomes more dense19. It is recommended to use fuel heaters to overcome the effects of cold weather onfuels.AA. TrueB. False20. Which of the 1.1 liter governor types use four governor flyweights to control rackmovement?BA. Type 1B. Type 2C. Type 3D. Type 4E. Type 5
LEGV4801-02- 21 -Lesson Plan9/02Small Engine Fuel SystemsLesson Plan 2 - Fuel SelectionObjectives: The student, on a written test, will be able to explain the characteristics of diesel fuelswith at least 70% accuracy. The student will be able to select proper fuels for Caterpillar engines on a written testwith at least 70% accuracy. The student, on a written test, will be able to explain proper fuel system maintenanceprocedures for Caterpillar engines with at least 70% accuracy.Literature Needed:Fuel Selection Slide ScriptDiesel Fuel and Your EngineHardware Needed:ProjectorScreenFuel Selection SlidesTime Required:1.25 HoursTasks Required by Instructor to Meet Objectives:1. Review the slides and emphasize the following points:A. Preferred fuelsB. The function of cetane in the fuelC. Water and sediment in the fuelD. The effect of low temperature on a fuel1. Cloud point2. Pour pointE. Methods of changing cloud / pour point of fuelCopySEBD0717
LEGV4801-02- 22 -Lesson Plan9/021. Gasoline2. Alcohol3. #1 DieselF. Sulfur in the fuel2. Using Diesel Fuels and Your Engine, emphasize the following points not on the slideprogram:A. The expense of fuel relative to other engine operating costs.B. Fuel contaminantsC. The effects of poor fuel quality on the engine.D. Charts of acceptable limits and problems and causes.E. Precombustion vs. Direct InjectionF. Fuel system maintenance3. Ask if there are any questions and review any areas that might be unclear.
LEGV4801-02- 23 -Slide/Text Reference9/02Small Engine FuelSystemsSLIDE 1During this course we will be discussing various types of fuel systemsused on our medium duty Caterpillar engines. Before we can discussvarious fuel systems, we must first talk about what they pump: Fuel
LEGV4801-02- 24 -Slide/Text Reference9/02Fuel SelectionSLIDE 2Attributes of fuelEngine performanceWe will discuss the attributes of fuel and how it affects the performanceof a diesel engine. Many people think that all fuel is the same, and thatit does not change engine performance. The inverse is probably morecorrect. During the next few minutes we will explore some of thedifferences that can be found in different fuels.
LEGV4801-02- 25 -Slide/Text Reference9/02SLIDE 3Service lifePerformanceFuel selectionCaterpillar wants its customers to get the maximum service life fromtheir engines with a minimum of downtime. One method to assure goodcontinuous engine performance is to select the best available fuel. Fuelquality is critical to engine life and good performance. Although calleddiesel fuel, the exact mixture could be slightly different with every fillup. Therefore, with every fill up, the engine may perform differently.
LEGV4801-02- 26 -Slide/Text Reference9/02Preferred FuelsDiesel FuelFuel OilFurnace OilGas OilSLIDE 4Preferred FuelsDistillate fuelsDiesel fuelCaterpillar engines have the ability to burn a wide range of fuels.Distillate fuels are the preferred fuels for use in Caterpillar engines.Those fuels are commonly called diesel fuel (number 1 or 2), fuel oil,furnace oil, gas oil or kerosene.Fuel oilGas oilKeroseneMaximum lifeExperience has proven that the use of distillate fuels will result inmaximum engine service life, performance and durability. Distillatefuels usually contain smaller amounts of water, sulfur and sediment thanthe second type of fuels, permissible.
LEGV4801-02- 27 -Slide/Text Reference9/02Preferred FuelsRequirementCetane # PCCetane # DIWater & SedimentAPI @ 60 min/maxSulfurStandard35 min40 min0.05% max30/450.5%Low Sulfur35 min40 min0.05% max30/450.05%Pour PointCloud Point10F below ambient temperatureNot higher than ambientSLIDE 5Standard sulfur 0.5%Low sulfur 0.05%Here are the Caterpillar specifications for preferred fuels. It is separatedinto two groups. Standard fuel, and low sulfur fuel. It should be notedthat the only variation between the two columns is the amount of sulfurcontained in the fuel.Each type ( diesel fuel, fuel oil, furnace oil, kerosene) of preferred fuelscan be put into either category depending on sulfur content.Standard fuel, 0.5% sulfur maximum (5,000 parts per million), isavailable for off highway use in heavy equipment, industrial enginesand commercial marine applications in the United States and Canada.For identity of this fuel, the governments require a dye to be added.Low sulfur fuel, 0.05% sulfur maximum (500 parts per million), isrequired for use on highway trucks and pleasure craft marineapplications in the United States and Canada. No dye is added to thisfuel. It is almost clear with a slight yellow green tint.
LEGV4801-02- 28 -Slide/Text Reference9/02As emission standards get tighter, new fuels are already available. Thenext step will be diesel fuels with 0.015% sulfur maximum (150 partsper million). These fuels will be required for on-highway use in 2007.They are currently in use for ultra low emissions vehicles.
LEGV4801-02- 29 -Slide/Text Reference9/02Permissible FuelsCrude OilsBlended FuelsSLIDE 6Permissible fuelCrude oilBlended fuelServiced lifeTreatmentCentrifugeHeatingReducing lifeIncreasedmaintenanceThe use of some crude oils and blended fuels, is permissible in someCaterpillar engines. These engines require a special fuel system totolerate the differences of these fuels.Crude oil is oil or fuel that is not yet refined or fully refined, and isbasically the same as it was originally pumped from the ground.Blended fuel, sometimes called heavy or residual fuel, is composed ofthe remaining elements from crude oil after the oil has been refined intodiesel fuel or gasoline. These elements can be combined or diluted witha lighter fuel so they can flow. At times these fuels have to be heated orcentrifuged to be used.If crude oil or blended fuels are used, additional service procedures maybe required, and reduced service life may be experienced.
LEGV4801-02- 30 -Slide/Text Reference9/02Permissible FuelsRequirementFuelsCetane # PCCetane # DIWater and SedimentAPI @ 60 min/maxSulfurPour PointCloud PointtemperatureCrude OilsBlended35 min40 min0.5%max30/450.5%35 min40 min0.5% max30/455.0%10F below ambient temperatureNot higher than ambientSLIDE 7Crude oilBlended fuelWater, sediment,trace metalsSulfur contentHere are the Caterpillar specifications for permissible fuels. Again, it isseparated into two groups, crude oil, and blended fuel. It should benoted that these fuels are allowed higher concentrations of water andsediment than are the preferred fuels.Beca
Sample Engine Performance Information from the TMI on-line system Copy Quiz 1 Copy 1.1 Liter Fuel System Slide Script Copy Systems OperationT&A,3114, 3116, 3126 Engines SENR3583 Torque Specifications SENR3130 Using the 128-8822 Tool Group on 3114, 3116, & 3126 Engines HEHS0610 Service Manual, 3114, 3116, 3126 Engine Governor SENR6454 Quiz 2 Copy
1.Engine Oil SABA 13 1.Engine Oil 8000 14 1.Engine Oil 6000 15 1.Engine Oil 3000 16 1.Engine Oil Alvand 17 1.Engine Oil Motor Cycle Engine Oil M-150 18 1.Engine Oil M-100 19 1.Engine Oil Gas Engine Oil CNG-BUS 20 1.Engine Oil G.I.C.X.LA 21 1.Engine Oil G.I.C.X. 22 1.Engine Oil Diesel Engine Oil Power 23 1.Engine Oil Top Engine 24
Fuel transfer pump (35) is mounted on the back of unit injector hydraulic pump (1). The fuel transfer pump pushes pressurized fuel out of the outlet port and the fuel transfer pump draws new fuel into the inlet port. Fuel is drawn from fuel tank (12) and flows through two micron fuel filter (11) . Fuel flows from fuel filter (11) to the inlet .
to fuel pump; as in the case of VW , or in-line between the fuel pump and engine for most other vehicles. See connection examples that follow. Typical 1/4″ Connection Fuel Line to Engine 1/4″ Hose (5) from Fuel Pump Typical 3/8″ Connection Fuel Line to Engine 3/8″ Hose (6) from Fuel Pump Connect Directly to Special Test Outlet on Engine
fuel pressure to the fuel injection pump. The pressure regulator regulates the fuel at an absolute pressure of 150 kPa (22 psi) when the engine is at idle speed. The fuel injection pump increases the fuel to a maximum pressure of 200 MPa (2900 psi). The fuel injection pump delivers the fuel to the high-pressure manifold (Rail). The fuel .
Small Engine Service and Repair Curriculum Guide: Small Engine Service and Repair Module: 4. Small Engine Compression Unit Objective: Students will demonstrate an understanding of small engine compression by identifying valve tools and their uses and inspecting and servicing the valve train of a small engine. Show-Me Standards: 1.10, CA3 References:
5-6 FUEL SYSTEM AND THROTTLE BODY FUEL TANK LIFT-UP Remove the front seat. ( 7-4) Remove the fuel tank mounting bolts. Lift and support the fuel tank with its prop stay. FUEL TANK REMOVAL Lift and support the fuel tank with its prop stay. (L7above) Disconnect the fuel pump lead wire coupler 10. Pla
Fuel Pressure: Fuel Pressure Regulator and System Pressure. Fuel System: Pumps, Relays . significant volume of fuel may come out. Be ready to catch all the gas in the filter . The 3 main things to check in the fuel circuit are the fuel pump relay, and the 2 fuel pumps. 1. Fuel Injection Relay Test
Form No. SHLSBCERT(2014) Page 1 41NVSHLCE_SB_COC_2014 P.O. Box 15645 Las Vegas, Nevada 89114-5645 Small Business Group Certificate Of Coverage THIS CERTIFICATE CONTAINS A DEDUCTIBLE Uments This Small Business Group Health Insurance Certificate of Coverage ("Certificate") contains the terms under which Sierra Health and Life Insurance Company, Inc. ("SHL") agrees to insure Eligible Employees .
