Caterpillar 168-7740 Caterpillar FuelCom Fuel Flow Measurement System Tool Operating ManuL

NEHS0740 July 1999

TOOL OPERATING MANUAL Using the 168-7740 Caterpillar FuelCom Fuel Flow Measurement System for 3600 Engines SMCS Code 0782, 1000, 1250

Data Logging Sub-Menu. . . . . . . . . . . . . . . . . . . 34 Tag Sub-Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Arrange Sub-Menu . . . . . . . . . . . . . . . . . . . . . . . 37

Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . 3

Data Logging Operation . . . . . . . . . . . . . . . . . . . . 38 Performing a Datalog . . . . . . . . . . . . . . . . . . . . . 38 Downloading the Logged Data. . . . . . . . . . . . . . 39

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Optional Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuel Flow Measurement System . . . . . . . . . . . . . 10 154-8106 and 154-8105 Fuel Flow Displays . . . 12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Internal Fuse Test/Replacement . . . . . . . . . . . . . 44 FuelCom Flowmeters . . . . . . . . . . . . . . . . . . . . . 44 Cleaning FuelCom Flowmeters . . . . . . . . . . . . 44 Check for Debris or Other Contamination . . . . 45 Remove Varnish From Bearings. . . . . . . . . . . . 45 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Communicating with DataView . . . . . . . . . . . . . . . 13 Connecting Flowmeter to DataView . . . . . . . . . . 13 Set-up the DataView . . . . . . . . . . . . . . . . . . . . . . 13 Communicating With Other Devices . . . . . . . . . . . 14 154-8106 and 154-8105 Fuel Flow Displays . . . . . 15 Controls and Indicators on the Display . . . . . . . 15 Front Panel Switches . . . . . . . . . . . . . . . . . . . . . 15 Mounting the 154-8105 Display . . . . . . . . . . . . . 18 Power for Fuel Flow Measurement System. . . . . 20 Connecting the Power Supply . . . . . . . . . . . . . 20 AC Power Operation . . . . . . . . . . . . . . . . . . . . 20

Checking the Operation of the Fuel Flow Monitor System . . . . . . . . . . . . . . . . . . . . 47 FuelCom Fuel Flowmeter Functional Test . . . . . . 47 Two FuelCom Flowmeter Functional Test . . . . . . 48 Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . 50

FuelCom Fuel Flow Measurement System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Two FuelCom Flowmeter System . . . . . . . . . . . . 23 Selection of Flowmeter Size and Type . . . . . . . . 23 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Installation Instructions . . . . . . . . . . . . . . . . . . . . 24

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . 27 Using the 154-8106 or 154-8105 Fuel Flow Display to Measure Fuel Flow. . . . . . . . . . . . . . . 27 Measuring Fuel Flow. . . . . . . . . . . . . . . . . . . . . . 27 Reverse Flow Rate Reading. . . . . . . . . . . . . . . 29 Interpretation and Conversion of Test Results. . . . 29 To Convert To Fuel Weight . . . . . . . . . . . . . . . . . 29 Brake Specific Fuel Consumption (BSFC) or Corrected Specific Fuel Consumption (CSFC) . 30 Multiple Display Operation . . . . . . . . . . . . . . . . . . 30 Programming the Function Switches (F1, F2, F3, F4, F5). . . . . . . . . . . . . . . . . . . . . . 31 Display Factory Reset. . . . . . . . . . . . . . . . . . . . . 31 Display Data Items for the Function Switches . . . . 32 Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . 33 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Main Menu Items . . . . . . . . . . . . . . . . . . . . . . . 33

2

NOTE: Another type of Caterpillar FuelCom Fuel Flowmeter Group is also available which allows using the older Caterpillar 8T-9300 Fuel Flow Monitor as a display. The part number for this group is 168-7730 Fuel Flowmeter Group. It contains only the FuelCom Flowmeters that will connect to the 8T-9300 Monitor and the necessary cables. The additional parts, such as the monitor and the Fuel Flow Power Supply can be reused from existing 1U-5450, 1U-5440, or 1U-5430 Caterpillar Fuel Flow Arrangements. For more information on this group refer to Tool Operating Manual Form NEHS0741 "Using the 168-7730 Caterpillar FuelCom Fuel Flowmeter Group for Use With the 8T-9300 Fuel Flow Monitor".

Introduction

Principle of Operation Illustration 1. Caterpillar FuelCom Fuel Flow Measurement System (sight glasses not shown).

The 168-7740 Caterpillar FuelCom Fuel Flow Measurement System, as shown in Illustration 1, is a portable test system designed to help evaluate engine performance. It uses two fuel flowmeters and a fuel flow display to: • Measure fuel flow and fuel temperature of both supply and return-to-tank fuel lines.

• Calculate the fuel burn rate of diesel engines.

Information on the average and total fuel burned by the engine over a period of time is also provided by the fuel flow display. Internal memory records 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.

Illustration 2. 168-7745 Flowmeters.

The 168-7740 Caterpillar Fuel Flow Measurement System Arrangement has a maximum operating range of 570 Lph (148 gph) to 4740 Lph (1232 gph). These flowmeters can be used with 3606, 3608, 3612, or 3616 Engines.

State of the art gear-type flowmeters are used with the 168-7740 Caterpillar FuelCom Fuel Flow Measurement System to measure fuel flow. Two of these 168-7745 Flowmeters are shown in Illustration 2. The flowmeter’s transmitter contains a microprocessor that linearizes the output signals, and temperature corrects the flow rates to provide accurate fuel flow and fuel temperature data.

NOTE: Contact CSTG for performing fuel measurements for engines larger than the 3616 Engine model.

The flowmeters connect to the fuel flow display using a junction box. This display shows fuel flow and fuel temperature information.

1U-5295 Accumulators installed on the engine’s supply and return lines are necessary for 3612 or 3616 Engine testing (refer to the Installation section for more information).

3

K-Factor

Each flowmeter will communicate directly with the 131-5050 Caterpillar DataView using a 168-7755 Cable.

The K-Factor, expressed in units of pulses per gallon (PPG) and pulses per liter (PPL), is stamped on the flowmeter’s name plate, as shown in Illustration 7. This represents the number of pulses per gallon of #2 diesel fuel and is temperature compensated to 16°C (60°F), API.

0698-02

Illustration 3. 168-7745 Fuel Flowmeter Operation.

FuelCom flowmeters use two rotating gears driven by fuel flow. Magnets imbedded in the gears activate a non-intrusive sensor, which generates a pulsed output signal. Each pulse represents a known volume of fuel that is captured between the lobes of the gears. The temperature of the fuel passing through the flowmeter is also measured by the non-obtrusive sensor. Both pulse and temperature data are sent to a microprocessor in the flowmeter’s transmitter. The pulse data is then compensated for temperature, and linearized to provide an accurate output signal.

4

Components

Illustration 4. 168-7740 Fuel Flow Measurement System Group.

(1) 168-7745 Fuel Flowmeters. (2) 168-7739 Sight Glass. (3) 154-8107 Junction Box. (4) 8T-9280 Fuel Flow Power Supply.

(5) 5P-7366 Power Cable for connection to machine battery. (6) 4C-9660 King Pelican Case (Decal NEEG2839, 168-7742 Component Foam Insert, and 154-8099 Lid Foam Insert also needed). (7) 154-8106 Fuel Flow Hand-Held Display.

(8) 154-8097 Cable for connecting 8T-9280 Power Supply to 154-8107 Junction Box. (9) 154-8095 Cable for connection from 154-8107 Junction Box to 168-7745 Flowmeter or 154-8106 Display. (168-7740 also includes, but are not shown: NEHS0740 Tool Operating Manual and NIST Traceable Flowmeter Calibration Certificates).

NOTE: 1U-5295 Accumulators installed on the engine’s supply and return lines are necessary for 3612 or 3616 Engine testing (refer to the Installation section for more information).

5

Optional Items

Illustration 5. Optional Items For Use With The Fuel Flow Measurement System.

Refer to Chart A for item identification.

6

Chart A. Optional Items For 168-7745 Fuel Flow Measurement Group Item

Description

Specification

1

168-7755 Cable, 5.5 m (18 ft)

Connects one 168-7745 Fuel Flowmeter directly to DataView.

2

4C-9660 King Pelican Case

168-7742 Component and 154-8099 Lid Foam Inserts also needed.

3

154-8095 Cable, 6.1 m (20 ft)

Used to connect 154-8107 Junction Box to 168-7745 Fuel Flowmeter or 154-8106 Fuel Flow Display.

4

154-8105 Fuel Flow Panel Mount Display

Connects to 154-8107 Junction Box instead of 154-8106 Fuel Flow Display.

5

154-8093 Extension Cable, 6.1 m (20 ft)

This cable connects between the 168-7745 Flowmeter and the 154-8095 Cable or the 154-8107 Junction Box and the 154-8095 Cable.

6

1P-7408 Thermo-Hydrometer

Range is 29 to 41° API.

7

5P-2712 Thermo-Hydrometer

Range is 39 to 51° API.

8

1P-7438 Beaker

Used for fuel density tests.

9

154-8096 AC Power Supply Group, 90/264 Volts AC, 47/63 Hz

Used for powering system without 8T-9280 Power Supply by connecting directly to 154-8107 Junction Box. It supplies 12-Volts DC, at 2.5 Ampere maximum current.

10

131-5047 AC Power Cable, 110 VAC (USA Plug)

Connects to 154-8096 AC Power Supply.

Additional Items Available (not shown) Item

Description

Specification

—

137-0171 European Power Plug Adapter

Connects to 131-5047 AC Power Cable.

—

133-6975 AC Power Cable, 220 VAC (European Plug)

Connects to 154-8096 AC Power Supply.

—

168-7739 Aluminum Sight Glass

Connects to 168-7745 Flowmeter.

7

Illustration 6. 168-7750 Hose/Adapter Group.

This group provides the basic components needed to connect the 168-7745 Flowmeters to Caterpillar engines for testing purposes. This hose/adapter group is used with the 168-7740 Fuel Flow Measurement System Group. Refer to Chart B for item identification.

Illustration 7. Accumulators.

Refer to Chart D for item identification.

8

Chart B. 168-7750 Hose/Adapter Group

1

Item

Qty.

Part No.

1

1

6V-7145

Carrying Case

2

1

NEEG2844

Decal (HOSE/ADAPTER GROUP)

3

1

1U-5365

Hose Size 16, 1 m (3 ft)

4

1

1U-5364

Hose Size 16, 0.3 m (1 ft)

5

4

5P-2299

Plug Size 16 Male

6

41

2P-8148

Nut Size 20

7

41

6V-0411

Reducer Size 20 Female to Size 16 Male

8

1

148-5675

Accessories Case

9

1

NEEG2061

Decal (Accessories)

10

2

9S-7754

Union, Size 16 Male

11

6

6V-7555

12

6

—

1

Chart C. Additional Hose Assembly For 3600 Engines

Description

Qty. 1

Part No. 168-7733

Description Hose Size 20, 1 m (3 ft)

Accumulators 1U-5295 Accumulators installed on the engine’s supply and return lines are necessary for 3612 or 3616 engine testing (refer to the Installation section for more information).

Chart D. Accumulators Item

Qty.

Part No.

Description

1

1

1U-5295

Accumulator Connects to 168-7736 Swivel Tee

2

1

168-7736

Swivel Tee, 37° Flare, Size 20, Connects to 1U-5295

Plastic Tie Strap 1020 mm (40 in)

3

1

NEEG2180

Decal Apply to 1U-5295

6V-6132

Plastic Tie Strap 203 mm (8 in)

—

1

3K-0360

O-Ring Seal, (package of 20) Place on swivel tee before installing 1U-5295

148-5677

Foam Block for 148-5675 Accessories Case (not shown)

—

1

5P-2963

Charging Adapter Needed to charge 1U-5295

These parts, used together, make up the reducers and may be supplied as single piece units.

Storage Location for Accumulators

Illustration 8. (1) Two 1U-5295 Accumulators each with a 168-7736 Swivel Tee installed stored with 168-7740 Fuel Flow Measurement System Components. (One accumulator and tee swivel is stored underneath the other.)

9

Specifications

Material Specifications Item

Description

Flowmeter type

Gear type meter with microprocessor linearized and temperature corrected digital output signal. Uses non-intrusive sensor, creating pulses from magnets imbedded in one of the gears.

Output signals

RS485 Communication - for operation with 154-8106 or 154-8105 Fuel Flow Display using the 154-8107 Junction Box. Also has a frequency output for communicating with DataView.

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

Flowmeter case material

Black anodized aluminum.

Case bolts

Grade 8 zinc plated alloy steel.

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

Shafts

316 stainless steel.

Gears

Aluminum.

The example that follows illustrates the formula:

Ball bearings

440C.

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

Flow straighteners Zinc plated alloy steel.

Supply Rate = 60 Lph (16 gph) Return Rate = 30 Lph (8 gph) Burn Rate = 30 Lph (8 gph) [(.5 × 16 gph) + (.5 × 8 gph)] ÷ 8 = (8 + 4) ÷ 8 = 12 ÷ 8 = ± 1.5% of Reading Maximum Error.

Temperature

Chart E. Measuring Range and Accuracy Description ± one display digit

Single Flowmeter Calibration Range and Accuracy

570 Lph (148 gph) to 4740 Lph (1232 gph) ± 0.5% of reading (Note A)

Two Flowmeter System Burn Rate Range

0 to 4740 Lph (0 to 1232 gph) Return meter’s fuel flow must be a minimum of 569 Lph (150 gph)

Fuel Temperature Range

-20 to +85°C (-4 to 185°F)

Fuel Temperature Accuracy

0.5°C (1°F), providing the fuel has been flowing through the flowmeter long enough to stabilize the reading.

168-7745 Fuel Flow Measurement System Group Weight

25 kg (55 lbs)

168-7750 Hose/Adapter Group Weight

8 kg (17 lbs)

Viton

Fuel Flowmeter Pressure Drop Specifications

The following specifications are for 168-7745 Flowmeters when used with the 154-8106 or 154-8105 Fuel Flow Display in a system to measure diesel fuel flow at 35° ± 1° API fuel density.

Accuracy of specifications

300 Series stainless steel.

O-ring

Viton is a registered trademark of DuPont Dow Elastomers.

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

Item

Shims

10°C

70°C

Maximum Flow 4740 Lph (1250 gph)

33.8 kPa (4.9 psi)

26.9 kPa (3.9 psi)

84% of Flow 3980 Lph (1050 gph)

25.5 kPa (3.7 psi)

20.0 kPa (2.9 psi)

70% of Flow 3316 Lph (875 gph)

19.3 kPa (2.8 psi)

12.4 kPa (1.8 psi)

40% of Flow 1895 Lph (500 gph)

4.1 kPa (.6 psi)

2.1 kPa (.3 psi)

16% of Flow 758 Lph (200 gph)

1.4 kPa (.2 psi)

0.7 kPa (.1 psi)

Note A: To achieve stated Flowmeter accuracy when testing 3612 or 3616 Engines, the 1U-5295 Accumulators must be installed on engine’s supply and return lines (refer to the Installation section for more information).

10

General Operating Specifications Item

Description

Ambient air operating temperature

0 to 105°C (32 to 221°F)

Fuel operating temperature range

4 to 70°C (40 to 160°F)

Storage temperature range

-40 to 100°C (-40 to 212°F)

Vibration

Designed to be mounted on operating Caterpillar products.

Flowmeter current

125 mA at 15 VDC (max) 70 to 80 mA (Typical)

Flowmeter voltage

12 to 36 VDC

Source options

1. Supplied by 154-8107 Junction Box. 2. From DataView using a special cable.

Maximum operating pressure

1700 kPa (250 psi)

Flow connections

37° flare, SAE Size 20 Male fittings with a flow straightener built into the inlet fitting.

Flowmeter electrical connection pinout (Five pin Male sealed connector

Pin No. 1 2 3 4 5

Function +RS485 Output +VDC Input DC Common Input Frequency Output -RS485 Input

1

Chart F. 8T-9280 Operating Specifications Item

5

2

Description

Type of power supply

DC to DC switching converter

Input voltage range

11 to 40 VDC

Input current

4 Ampere maximum

Output voltage

12.0 ± 0.5 VDC

Output current

1.0 Ampere maximum

Line Regulation

± 0.25 volts maximum ± 0.1 volts (at 25°C)

Operating temperature

-40 to 60°C (-40 to 140°F)

4 3

Flowmeter weight

Illustration 9. (1) Flowmeter’s Name Plate.

(2) Transmitter’s FuelCom Decal. (3) Flowmeter’s Calibration Decal.

0698-20

Chart G. 154-8096 Operating Specifications

4.1 kg (9.0 lbs)

Item

11

Description

Type of power supply

AC to DC converter

Input voltage range

90 to 264 VAC, 47 to 63 Hz

Input current

1 Ampere at 110 VAC

Output voltage

12 VDC ± 5%

Output current

2.5 Ampere

Ripple

120 mV

Operating temperature

0 to 40°C (32 to 104°F)

154-8106 and 154-8105 Fuel Flow Displays

Chart H. Operating Specifications (Continued) Item

The following are Fuel Flow Display specifications for 154-8106 and 154-8105. Power for the display is supplied by 8T-9280 Fuel Flow Power Supply or the 154-8096 Power Supply Group through the 154-8107 Junction Box.

Chart H. Operating Specifications Item Display

Description

1

Backlit super twist LCD, 3/16 inch high characters.

4 rows by 20 characters per row.

5 by 7 pixel character resolution.

Burn rate display range 0.00 to 9999.99 Lph or gph Average burn rate display range

0.00 to 9999.99 Lph or gph

Total fuel burn quantity display range

0 to 9,999,999 liters or gallons

Supply rate, return rate resolution

0.0378 lph (0.01 gph)

Burn rate resolution

0.0378 lph (0.01 gph)

Burn average resolution 0.00 to 378.99 lph = 0.0378 lph (0.00 to 99.99 gph = 0.01 gph) 379.0 to 9999.9 lph = 0.378 lph (100.0 to 9999.9 gph = 0.1 gph) Burn total resolution

0.00 to 37,899.99 lph = 0.0378 lph (0 to 9999.99 gph = 0.01 gph) 37,900.0 to 9,999,999 lph = 0.378 lph (10,000.0 to 9,999,999 = 0.1 gph)

Display update rate

Once each second

Error codes

Refer to "Operating Instructions" in this manual.

Negative flow rates

Refer to "Operating Instructions" in this manual.

Operating temperature range

0 to 50°C (32 to 122°F)

Storage temperature range

-20 to 70°C (-4 to 158°F)

Humidity

Maximum of 90% non-condensing

154-8106 Display Size

104.0 × 182.0 × 25 mm (4.09 × 7.17 × 1.0 in)

154-8106 Display Weight

226 g (8 oz) without protective boot

154-8105 Display Size

126 × 126 × 36 mm (5.0 × 5.0 × 1.4 in) (without custom mounting bezel)

154-8105 Display Weight

370 g (13 oz)

Power

7.5-12 VDC, 100 mA maximum supplied by 8T-9280 Power Supply or 154-8096 AC Power Supply Group

12

Description

Interface connector

Five pin dual key-way 1 MicroChange® connector (male)

Memory

256 K battery-backed static RAM, 128 K flash EEPROM

Battery back-up

CR1632 (coin type 3 VDC lithium, up to 5 year life)

Real time clock

Dallas semi-conductor DS1994L-F5 [integrated lithium power cell with up to 10 year life at 25°C (77°F)]

MicroChange® is a registered trademark of Woodhead Industries, Inc.

4. Repeat Steps 1 through 3 to connect the other 168-7745 Flowmeter to DataView.

Communicating with DataView The 168-7755 Cable can be used to communicate from a 168-7745 Flowmeter directly to 131-5050 DataView. The DataView can monitor, graph, and Data Log the 168-7745 Flowmeter’s fuel flow information, but no fuel temperature information.

Illustration 11. One 168-7755 Cable Connected To DataView.

Set-up the DataView 1. Turn DataView ON and start the PC based program. Click on the Setup Tool icon.

Illustration 10. Two 168-7745 Flowmeters Connected To DataView.

(1) 168-7755 Cables. (2) 168-7745 Flowmeters.

(3) 131-5050 DataView.

2. Set-up each Frequency Channel that has a flowmeter connected to it: a. Double click on the Frequency Channel that has a flowmeter connected to it.

Connecting Flowmeters to DataView

b. Select from "Available Sensors" the "168-7745 Sup Fuel" sensor type if the flowmeter is connected to the engines supply or "168-7745 Ret Fuel" sensor type if the flowmeter is connected to the engines return line.

1. One 168-7755 Cable is needed for each 168-7745 Flowmeter. Connect cable’s connector labeled "168-7755 FUELCOM/DATAVIEW" into the 168-7745 Flowmeter’s connector.

c. Click on "OK" to choose the sensor.

2. Connect the 168-7755 Cable’s connector labeled "TO DATAVIEW ANALOG CHAN" into an available Analog Channel on DataView (DataView provides power to the flowmeter).

See Illustration 11.

d. Repeat Steps 2a through 2e to set-up the other flowmeter on DataView. e. View the sensor’s outputs on the Status Screen of DataView.

3. Connect the 168-7755 Cable’s connector labeled "TO DATAVIEW FREQ CHAN" to an available Frequency Channel on DataView (provides fuel flow information, but no fuel temperature information to DataView).

See Illustration 11.

NOTE: The DataView’s Analog Channel connected to the flowmeter provides power to that flowmeter.

The Analog Channel is automatically set-up when the cable is connected and the sensor type is defined as "FuelCom Fuel Power" (168-7755 Cable has an Auto-ID).

13

3. To display the burn rate:

Communicating With Other Devices

a. Click on an available "Calculated Channel". b. Select the "Burn Rate" Calculation.

For interfacing the 168-7745 Flowmeter’s frequency output to other devices: Frequency output is an NPN transistor that is an open collector output. Pull-up the output through a resistor to a 9-36 VDC. The maiximum sinking current is 50mA at 36 VDC. Choose a minimum sinking current of 100 mA by the selection of the pull-up resistor and voltage to achieve a turn-off voltage of <0.5 VDC (transistor saturated). This provides fuel flow information, but no fuel temperature information.

c. Define Channel 1 as the Frequency Channel set-up with "168-7745 Sup Fuel". d. Define Channel 2 as the Frequency Channel set-up with "168-7745 Ret Fuel". e. Click on "OK".

14

154-8106 and 154-8105 Fuel Flow Displays

®

Controls and Indicators

1

Illustrations 9 and 10 show the location of the indicators and touch type switches on the front of the 154-8106 and 154-8105 Displays.

154-8105 FUEL FLOW DISPLAY

4

3

5 2

NOTE: The touch switches must be pressed and held until the display changes.

7

ENG 1 ENG 2

10

TEMP

11

TIME

7

8

9

4

5

6

F4

F5

PRINT

BOTH

1

F1

MENU CTRL SHIFT

2

F2

0 RESET

3

9

ENTER

12

F3

16 8

13

14

6

AVG TOTAL

15

17

1 0697-05

®

Illustration 13. 154-8105 Display.

FUEL FLOW DISPLAY

12 F1 F2 F3 F4 F5

2 3 7 8 10 9 11 13 16

ENG 1 ENG 2 BOTH

TEMP

TOTAL

TIME

7 8 9

PRINT

4 5 6

CTRL

1 2 3

MENU SHIFT RESET

14

AVG

0

4 5 6 18

1. Digital Display: The LCD (liquid crystal display) with backlighting.

The display and its backlight will always be ON whenever power is applied to the 154-8106 or 154-8105 Display.

17

ENTER

15

Front Panel Switches 2. ENG1: Displays Engine 1 supply, return, burn, flow rates, and fuel temperatures on the display simultaneously. (This switch is disabled while in the Menu Mode.)

0697-04

Illustration12. 154-8106 Display (shown without protective boot).

Display

15

Definition

ENG1 SUP

Flow rate of the Engine 1’s supply line.

ENG1 RET

Flow rate of the Engine 1’s return line.

ENG1 BURN

Burn rate of Engine 1.

S1

Temperature of fuel in the flowmeter in Engine 1’s supply line.

R1

Temperature of fuel in the flowmeter in Engine 1’s return line.

GPH or LIT will appear after each fuel rate to indicate units.

DEG.F or DEG.C will appear after each temperature to indicate units.

3. ENG2: Displays Engine 2 supply, return, burn, flow rates, and fuel temperatures on the display simultaneously. (This switch is disabled while in the Menu Mode.)

Display

Definition

ENG2 SUP

Flow rate of the Engine 2’s supply line.

ENG2 RET

Flow rate of the Engine 2’s return line.

ENG2 BURN

Burn rate of Engine 2.

S2

Temperature of fuel in the flowmeter in Engine 2’s supply line.

R2

5. AVG: Displays the average burn rate and the time over which the average was accumulated for both Engine 1 and Engine 2 on the display simultaneously. (While in the Menu Mode, this switch is disabled for the 154-8106 Display and numeric "8" for the 154-8105 Display.)

Temperature of fuel in the flowmeter in Engine 2’s return line.

GPH or LIT will appear after each fuel rate to indicate units.

Display

DEG.F or DEG.C will appear after each temperature to indicate units.

4. BOTH: Displays the burn rate and average burn rate for both Engines 1 and 2 on the display simultaneously. (While in the Menu Mode, this switch is disabled for the 154-8106 Display and numeric "7" for the 154-8105 Display.)

Display

Definition

ENG1 AVG

Average burn rate of Engine 1.

E1A TIME

Time over which average burn rate of Engine 1 was accumulated.

ENG2 AVG

Average burn rate of Engine 2.

E2A TIME

Time over which average burn rate of Engine 2 was accumulated.

GPH or LIT will appear after average to indicate units.

—

GPH or LIT will appear after average to indicate units.

—

6. TOTAL: Displays the total burn rate and the time over which the burn was accumulated for both Engines 1 and 2 on the display simultaneously. (While in the Menu Mode, this switch is disabled for the 154-8106 Display and numeric "9" for the 154-8105 Display.)

Definition

ENG1 BURN

Burn rate of Engine 1.

GPH or LIT will appear after each fuel rate to indicate units.

ENG1 AVG

Average burn rate of Engine 1.

ENG2 BURN

Burn rate of Engine 2.

Display

ENG2 AVG

Average burn rate of Engine 2.

ENG1 TOT

Total burn rate of Engine 1.

E1T TIME

Time over which total burn rate of Engine 1 was accumulated.

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Definition

ENG2 TOT

Total burn rate of Engine 2.

E2T TIME

Time over which total burn rate of Engine 2 was accumulated.

GPH or LIT will appear after total to indicate units.

— GPH or LIT will appear after total to indicate units.

—

11. Scroll Down: Pressing this switch moves the cursor down one line at a time. It can be used in the Main Menu, Data Logging Sub-Menu, and while programming the Function Keys.

7. TEMP: Simultaneously displays the supply and return flowmeter’s fuel temperatures for both Engines 1 and 2. (This switch is disabled while in the Menu Mode.)

Display

12. Function Switches: (F1, F2, F3, F4, and F5) The function switches are user programmable switches. When pressed while in the Normal Display Mode, each function switch will change the display to show the parameters the user selects from a predefined list of choices.

Definition

E1S TEMP

Temperature of fuel in the flowmeter in Engine 1’s supply line.

E1R TEMP

Temperature of fuel in the flowmeter in Engine 1’s return line.

E2S TEMP

Temperature of fuel in the flowmeter in Engine 2’s supply line.

E2R TEMP

Temperature of fuel in the flowmeter in Engine 2’s return line.

DEG.F or DEG.C will appear after each temperature to indicate units.

NOTE: These switches are disabled while in the Menu Mode for the 154-8106 Display and are the numerical value shown on each switch’s pad for the 154-8105 Display.

13. CTRL: This switch is pressed and held and then the RESET is pressed to perform a factory reset.

8. TIME: Displays the burn rate total times for both Engines 1 and 2, the stopwatch timer, and the real time clock time on the display simultaneously. (This switch is disabled while in the Menu Mode.)

Display

14. SHIFT: This switch is pressed and held and then the RESET switch is pressed to perform a reset (i.e. reset the average burn rate, total burn rate, or stopwatch). The cursor must be positioned on the correct display line before the switches are pressed.

Definition

E1T TIME

Time over which total burn rate of Engine 1 was accumulated.

E2T TIME

Time over which total burn rate of Engine 2 was accumulated.

STOPWATCH

Stopwatch timer.

CLOCK

Real time clock.

15. RESET: This switch is pressed after the SHIFT switch has been pressed and held to perform a reset. (i.e. reset the average burn rate, total burn rate, or stopwatch). The cursor must be positioned on the correct display line before the switches are pressed. This switch is also pressed after the CTRL switch has been pressed and held to perform a factory reset.

9. PRINT: Pressing this switch activates the log memory function, that stops all other operations, and transmits all logged data through the RS-485 Port. The user will be required to confirm this selection by pressing the F1 key to continue with the transmission, or the F5 key to abort the action. (While in the Menu Mode, this switch is disabled for the 154-8106 Display and numeric "6" for the 154-8105 Display.)

Display PRINT LOG DATA NOW?

16. MENU: Pressing this switch while in the normal display mode will cause the display to enter the Menu Mode and vice-versa. This switch is also pressed to exit the DATA LOGGING TAG Sub-Menus.

17. ENTER: While in the Normal Display Mode, this switch scrolls forward through the list of available display data items when one of the F1-F5 function switches has been pressed.

This is used for selecting display items to save one of the F1 thru F5 keys. In the Menu Mode, the ENTER switch selects menu item, confirms changes to menu options, or tags items for data-logging.

Options F1-YES

F5-NO

18. Numeric Switches: These switches are used to enter numeric values while in the Menu Mode. They are disabled while in the Normal Display Mode.

10. Scroll Up: Pressing this switch moves the cursor up one line at a time. It can be used while in the Menu Mode and while programming the function keys in the Normal Display Mode.

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Mounting the 154-8105 Display

Illustration 14. Mounting Options Of 154-8105 Panel-Mount Display. Refer to the information on the next page for additional mounting instructions.

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Bezel Mount: An optional bezel is supplied to allow simple installation through the front of the panel. With the use of the bezel gasket, this method allows the display’s housing to create a seal with the front panel.

Surface Mount: The display has mounting slots that allow it to be snapped onto fasteners which are partially un-screwed from the panel.

NOTE: This arrangement does not provide sealing for the display’s housing to front panel interface.

Sandwich Mount: The display may be separated into two halves and reassembled with the panel sandwiched between the two halves. The display’s front housing can be sealed to the panel using the enclosure gasket. The internal connector must be separated to install unit.

NOTE: Note the orientation of the connector before removing the connector from the front half. Display may be damaged if connector is reversed when reassembled to the front half.

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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’s positive terminal.

Power for Fuel Flow Measurement System

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 the power has been supplied, place POWER ON switch (2) in the ON position. The POWER ON indicator (4) should light and an indication should be seen on the monitor display.

Illustration 15.

8T-9280 Fuel Flow Power Supply.

AC Power Operation Power for the 8T-9280 Fuel Flow Power Supply comes from external 11 to 40 Volts DC from the machine’s or engine’s battery.

Connecting Power Supply

Illustration 17. (1) 154-8096 AC Power Supply Group’s Cable. (2) Supply Connector on 154-8107 Junction Box. (3) 131-5047 AC Power Cable Connector. (4) 154-8096 AC Power Supply Group. (5) AC Power Cable Plug.

The 154-8096 AC Power Supply Group operates from 90 to 264 VAC. It can be used in the USA (120 VAC) and most other countries (240 VAC).

Illustration 16. (1) 8T-9280 Power Supply. (2) Power On Switch. (3) Output Connector. (4) Power On Indicator.

(5) Supply Connector on the 154-8107 Junction Box. (6) 5P-7366 Power Cable. (7) 154-8097 Cable.

1. Connect the 154-8096 AC Power Supply Group’s Cable (1) to The SUPPLY connector on 154-8107 Junction Box (2).

1. Connect one end of the 154-8097 Cable (7) to SUPPLY connector on the 154-8107 Junction Box (5), as shown in Illustration 12. Connect the other end to OUTPUT connector (3) on 8T-9280 Power Supply (1).

2. Connect 131-5047 AC Power Cable’s Connector (3) to the INPUT of the 154-8096 AC Power Supply Group (4). Plug the AC power cable’s plug (5) into an AC outlet.

NOTE: For operation outside the USA, use a AC power plug adapter, a 133-6975 AC Power Cable (European Plug), or replace the AC plug.

2. Connect 5P-7366 Power Cable (6) to the INPUT 11-40 VDC connector on 8T-9280 Power Supply.

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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 gears to drag. The recommended filter’s mesh size is sieve #60 and 250 micron.

FuelCom Fuel Flow Measurement System Installation The Caterpillar FuelCom Fuel Flow Measurement 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.

Illustration 18. Some of these parts may be located on the engine.

NOTE: The accumulators are not required when testing 3606 and 3608 Engines.

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Caterpillar FuelCom® Fuel Flow Measurement System

Illustration 19. Caterpillar FuelCom® Fuel Flow Measurement System. (Both the 154-8106 Hand-Held and 154-8105 Panel-Mount Displays are shown). FuelCom® is a registered trademark of Flowdata, Inc.

NOTE: Accumulators not shown, which are necessary for 3612 or 3616 Engine testing.

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Two FuelCom Flowmeter System Most Caterpillar engines have a return line that returns enough fuel to the fuel tank to permit the use of the 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 and return lines. (Two flowmeters required.)

• Engine fuel system does not have to be altered.

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

NOTICE Do not use the 168-7745 Flowmeters for a one flowmeter system setup. They are not designed for single meter operation.

Also, on some engines the return fuel is used for cooling and lubricating the fuel pump. A one flowmeter system would require plugging the return line, which could result in damage to the engine.

Selection of Flowmeter Size and Type 1. Refer to the engine lists and specifications to determine if these flowmeters are appropriate for your application. Caterpillar engine adaptability is also given for these flowmeters size and type in this manual, as shown in the FuelCom Flowmeters section of this manual.

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

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

Determine if these flowmeters may be used for a given application 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.

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Installation Use the following procedure to connect one 168-7745 Flowmeter into the engine fuel system supply line and the second 168-7745 Flowmeter into the engine return line. Although every engine installation cannot be covered here, this procedure will give the basic connection method for a two flowmeter system.

Illustration 16 shows the fuel flowmeters installed in the best locations. The flowmeter installed in the supply line is between the primary fuel filter and the fuel transfer pump. The flowmeter installed in the return line is located in the return-to-tank fuel line.

NOTE: Each flowmeter has a transmitter which must be used with its matched flowmeter body.

The transmitter and flowmeter body are matched using a "METER S/N", which is located on the transmitter’s FuelCom decal and the flowmeter body’s name plate (refer to Illustration 8). The two components are calibrated together. Make sure each flowmeter’s transmitter is screwed COMPLETELY into the flowmeter body mounting hole to ensure proper operation. The transmitter and flowmeter’s body come from the factory screwed together. Finger tighten only if needed.

The transmitter and flowmeter body can be damaged from over-tightening.

Illustration 20. Charging The Accumulator.

(1) Decal. (2) Accumulator. (3) Boss (size 8) Hex Nut on Swivel Tee. (4) Swivel Tee.

4. The 1U-5295 Accumulator, now assembled to the 168-7739 Swivel Tee, 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.

Charging the Accumulator NOTICE The flowmeter’s transmitter must be installed anytime the flowmeter is pressurized to help prevent damage to the transmitter hole from any sudden burst of pressure. Do not remove the transmitter from the flowmeter until the pressure has been reduced to 50% of the pressure rating stamped on the flowmeter’s name plate.

Assemble 1U-5295 Accumulator to 168-7736 Swivel Tee 1. Place NEEG2180 Decal (1) on 1U-5295 Accumulator (2).

2. Install 3K-0360 O-Ring Seal on 168-7736 Swivel Tee’s size 8 Boss (3).

3. Install 1U-5295 Accumulator onto 168-7736 Swivel Tee’s size 8 Boss by screwing it on by hand. Then tighten the size 8 Boss’s hex nut with a wrench. Refer to Illustration 20.

Illustration 21.

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

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

Installation Instructions 1. Determine the location of the flowmeters.

3. Screw the 5P-2963 Charging Adapter into the end of accumulator (1) (make sure the seal that comes with the 5P-2963 is first installed on the 5P-2963).

a. Compare the fuel system diagram, Illustration 16, to the actual fuel system on the engine being tested. b. Check 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 flowmeters and sight glasses are normally installed using hoses to connect into the fuel lines.

4. Charge the accumulator using the 5P-2963 Charging Adapter with 69 KPa (10 psi) to 103 KPa (15 psi) of nitrogen.

5. Remove the 5P-2963 Charging Adapter and replace screw (1).

NOTE: Remove the 5P-2963 Charging Adapter quickly to prevent leakage of nitrogen.

c. Determine the type of fuel pump being used.

If the engine has a gear-type fuel transfer pump, the flowmeter can be installed either before or after the pump. If a piston-type pump is being used, the flowmeter must be installed only on the inlet side of the pump.

NOTE: If the pressure in the accumulator is not correct, the flowmeters may give inaccurate readings. Check the charge in the accumulator at least once every 12 months. See Illustration 22.

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.

NOTE: If the flow meter is installed between the fuel filter and fuel injection pump, 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. a. Select the fittings from the 168-7750 Hose/Adapter Group, which includes some of the parts needed for connecting the flowmeters to Caterpillar engines. The connections to the flowmeter and sightglass are standard 37° flare, SAE size 20 fittings (sight glass installed directly to flowmeter’s outlet).

Illustration 22. Checking The Accumulator’s Pressure.

(1) 1U-5295 Accumulator. (2) 5P-2963 Charging Adapter. (3) Pressure gauge.

NOTE: If a particular fitting is not part of this group it can be obtained from an industrial supply company, or from the Caterpillar dealer. b. Select the hoses. Usually a 0.3 m (1 ft) long hose can be used on one end and a 1.0 m (3 ft) long hose on the other end.

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6. Connect and tighten the hoses and fittings to the flowmeter, sight glass, and accumulator. 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.

c. It is recommended to install a filter up stream from each flowmeter. An upstream filter will prevent large particles in the diesel fuel from jamming or damaging the flowmeter. The recommended mesh size is sieve #60 and 250 micron.

7. Close the fuel shutoff valve at the fuel tank.

Use tie straps to attach the flowmeter to the engine, near the installation location.

NOTE: The JIC fitting at the inlet of the flowmeter, as shown in Illustration 23, also functions as a flow straightener. Removal of the inlet fitting will adversely affect the flowmeter’s accuracy.

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

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

9. Install the flowmeter. a. Loosen and remove the fitting connecting the fuel lines. Some installations may require removal of a fuel line. In some other installations, the fuel line that is disconnected may be connected directly to the flowmeter b. Install the flowmeter lines making sure the fuel IN and OUT, which is stamped on top of flowmeter and on opposite ends, is in the same direction that fuel will be flowing.

Illustration 23.

(1) Built-In Flow Straightener. (2) SAE Inlet Fitting.

NOTE: Each flowmeter must be positioned so the flowmeter’s transmitter is positioned vertically in all directions, ± 10°, as shown in Illustration 24.

3. Install the 168-7739 Sight Glass on the outlet fitting of each flowmeter. The top of the flowmeter’s body is stamped "IN" and "OUT" for identification of proper flow direction.

Skip steps 4 and 5 when testing 3606 and 3608 Engines.

NOTE: The accumulators must be installed to the T-adapters using the "Assemble Accumulators to T-adapter" section before performing Steps 4 and 5.

4. Install the accumulators T-adapter to the supply flowmeter’s outlet fitting. If a sight glass is installed, then install the accumulator after the sight glass.

5. Install the other accumulator’s T-adaptor to the return flowmeter’s inlet fitting.

Illustration 24.

d. Tighten the hose fittings so they will not leak.

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b. 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.

10. Purge the air from the 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.

c. To eliminate air from the fuel: 1) Make sure all fittings are tight. 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 not be possible 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.

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. a. Several methods, dependent on the type of fuel system, can be used to purge the air from the fuel: 1) Open the fuel shutoff valve at the fuel tank.

2) Run the engine until the fuel is free of air bubbles (small bubbles).

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

d. Some manufacturer’s 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.

3) Tighten fitting after air has been purged.

This method will reduce the aeration.

14. Run the engine at High Idle speed and observe the flow readings on the display.

b. If these methods do not reduce aeration to an acceptable level, a De-Aerator Group and De-Aerator Tank may be required. The De-Aerator Group and De-Aerator Tank are fabricated tooling and the FT drawings are available from CSTG. Contact CSTG for more information.

a. Refer to "Using the Fuel Flow Displays to Measure Fuel Flow" section in this manual for more information on obtaining the flow readings.

11. Use the 154-8095 Cables to connect the 168-7745 Fuel Flowmeters and 154-8106 or 154-8105 Fuel Flow Display to the 154-8107 Junction Box.

b. 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.

a. Connect the 168-7745 Flowmeters to any of the junction box’s ports (1 through 6).

Connect the 154-8106 or 154-8105 Fuel Flow Display to the junction box’s "FUEL FLOW DISPLAY" port. b. Use 154-8093 Extension Cables, if required.

Refer to the "Optional Items" section in this manual for additional information. c. Provide power for the flowmeters and display. Refer to "Power For Fuel Flow Measurement System" section in this manual.

12. Start the engine and check for fuel leaks.

Correct any leaks that are found.

13. Check for air leaks. a. Check for air in the fuel by observing the fuel flow through the sight glass connected to each flowmeter.

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c. 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.

Operating Instructions Using the 154-8106 or 154-8105 Fuel Flow Display to Measure Fuel Flow

2. Steps to Setup Display for Operation: The operational setup programmed into the display, which is described in the following steps, is retained even if power is removed to the display. At power-up, the display will show an initialization screen, which includes the software version number, for 5 seconds. After the initialization is complete, push the MENU switch to Enter the Menu Mode. Push the scroll up ↑ or scroll down ↓ switch until the cursor is on the TOTALIZER line. If it shows TOTALIZER STARTED, then Press ENTER switch. If it shows TOTALIZER STOPPED, then go to Step 3.

Before using the fuel flow display, refer to the following sections in this manual: • Controls and Indicators on the Display • Power for the Fuel Flow Measurement System When using the fuel flow display, 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 up to eight seconds after correcting a problem, before the code will disappear. The following chart contains the codes and their description.

3. Scroll up or down to move the cursor to the line showing "VOLUME UNITS=" and "GPH" or "LIT" will be shown to the right of "VOLUME UNITS=".

Change from GPH (gallons per hour) to LIT (liters per hour) or vice versa by pressing the ENTER switch. (See Note.)

4. Scroll up or down to move cursor to the line showing "TEMP UNITS=" with "Deg.F" or "Deg.C" shown to the right of "TEMP UNITS=".

Press ENTER switch to change from "Deg.F" to "Deg.C" or vice versa. (See Note.)

General Codes WARNING: COMM LOST (flashes on bottom display line in all display modes)

Flowmeter is not connected to junction box or a wire(s) is broken for flowmeter(s) that have their address number(s) entered in the Main Menu. An incorrect flowmeter address could have been entered.

LOST!

Flashes on the display line of the flowmeter parameter that can no longer display a correct value because communications are lost. The same cause as for "WARNING: COMM LOST", but LOST! shows which parameter. Indicates that in the Menu Mode "00000" was entered for a flowmeter, which indicates to the display that the flowmeter does not exist.

NOTE: If "ERR: LOGGING ACTIVE" is momentarily displayed when ENTER switch is pressed on this display line, then LOGGING is ON. Refer to the Data Logging Sub-Menu section.

5. Use scroll up ↑ or scroll down ↓ switch to select ENG1 SUP ADR (Engine 1 Supply Address).

Push ENTER switch and key in the "ADDRESS NO." using numeric numbers of the flowmeter installed in Engine 1’s Supply Line. (See Note.)

Then press ENTER to save the "ADDRESS NO." in the display’s memory.

WARNING: Underflow UNDERFLOW The fuel flow being measured is lower than the minimum specification of the flowmeter.

WARNING: OVERFLOW

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

NOTE: Press the ENTER switch and key in the 5 digit "ADDRESS NO." located on the flowmeter’s Transmitter FuelCom Decal (Illustration 7). Keying in "00000" on a specific flowmeter address line "turns off" this flowmeter.

If a flowmeter is "turned off", then the display will not show fuel parameter data for this flowmeter while in the Normal Display Mode and instead will display "-OFF-". If "00000" is not keyed in for the flowmeter address, then it must match the "ADDRESS NO." on the flowmeter’s Transmitter FuelCom Decal.

Measuring Fuel Flow 1. Connect power to the junction box. a. Connect the flowmeter(s) and display as described in the specific installation instructions. b. After power is connected to the junction box, the display will require 30 seconds for a good reading to appear.

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12. Press the TOTAL switch and the amount of fuel burned and the time(s) accumulated will be shown on the display for the engine(s). To reset the total(s) to 0 (zero) and restart the timer(s), use the scroll up or scroll down switch to place the curser on the beginning of line showing "ENG1 TOT" or "ENG2 TOT", hold the SHIFT switch and then press the RESET switch.

6. Scroll up or down to the "ENG1 RET ADR." Push ENTER switch and key in the address of the flowmeter installed in Engine 1’s Return Line, then press ENTER. 7. Repeat Step 5, but for Engine 2’s supply and return flowmeters (if flowmeters are installed on a second engine). If there is no Engine 2, then key in "00000" instead of the "ADDRESS NO." and the display will show "--OFF--" for data when the ENG2 switch is pressed.

13. To read the average burn rate since the start of the test for the engine(s), press the AVG switch. To start a new average(s), use the scroll up and scroll down switches to place the curser on the beginning of "ENG1 AVG" or "ENG2 AVG", press and hold the SHIFT switch and then press the RESET switch.

8. Use scroll up or scroll down switch to select TOTALIZER STOPPED and press ENTER to start the Totalizer again.

9. Press MENU switch to return to Normal Display Mode.

14. Display the burn rate total time(s) for the engine(s), the stopwatch, and the real time clock by pressing the TIME switch. Reset the STOPWATCH by moving the cursor to the STOPWATCH’S line. Press and hold the SHIFT switch and then press the RESET switch. The CLOCK can only be altered by modifying the "SET TIME" line in the MAIN MENU. (Refer to the Main Menu section.)

10. Read the temperature of the fuel supply flowmeter of the engine(s) by pressing the TEMP switch. a. The fuel temperature will appear on the display, followed by a DEG.C (for Centigrade), or a DEG.F (for Fahrenheit). b. The temperature will register even if the engine(s) is not operating.

11. After the engine(s) is operating, fuel flow and temperatures in the supply and return flowmeters, plus the burn rate, can be observed. a. To display fuel flows and burn rate(s): press ENG1 switch for Engine 1, ENG2 switch for Engine 2, or the BOTH switch for both engines. The display will indicate either LIT (liters per hour) or GPH (gallons per hour) to the right of the displayed flow for each flowmeter and also the burn rate. b. If the flow through the flowmeter selected is below, or above, the rating of the flowmeter that is connected, the display will indicate either "WARNING: OVERFLOW" or "WARNING: UNDERFLOW". c. To display temperatures of fuel measured by flowmeters: press the TEMP switch.

Units of DEG.F or DEG.C will be shown to the right of each temperature.

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Reverse Flow Rate Reading

Interpretation and Conversion of Test Results

There is no indication for reverse flow (flow through a flowmeter in the direction opposite the IN and OUT identifications, which are stamped on top of the flowmeter’s cover and identify the two JIC fittings for installation). Any reverse flow through the flowmeter will be displayed as a positive flow no matter if the flowmeter is setup as a supply or return flowmeter in the display. The flowmeter with flow passing through it in a reverse direction will most likely make a rattling sound as the gears are turning. Fuel passing through the flowmeter in the reverse direction will not damage the flowmeter.

The fuel flow reading displayed will not be accurate, compared to the flowmeter’s specifications, because the flowmeter is calibrated in the forward direction only.

The Caterpillar Fuel Flow Measurement 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 the 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 ± 1°. 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" section in this manual. They are needed to determine the fuel density for conversion to other units of measure.

A negative burn rate is shown with a minus (-) sign on the left side of the burn rate value. This will happen if the "ADDRESS NO." of the flowmeter installed in the engine’s supply line is keyed into the display on the return flowmeter line instead of the supply flowmeter line in the Menu Mode. The same is true for the "ADDRESS NO." of the flowmeter installed in the engine’s return line.

Reversing the supply and return flowmeter cables will not cause this problem because the display communicates with each flowmeter using each flowmeter’s unique "ADDRESS NO." A negative burn rate may also be caused when 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.

A Special Instruction, Measuring API Gravity is also needed. Contact CSTG to obtain a copy.

To Convert to Fuel Weight Use the procedure in Special Instruction, Measuring API Gravity to measure the API gravity and temperature of the diesel fuel. Determine the corrected API gravity number from the chart.

If a negative flow rate is measured, then the amount will be subtracted from the burn TOTAL and burn grand total (G.TOT) numbers and the burn AVG number will also decrease.

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

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

If the burn TOTAL, burn grand total (G.TOT), or burn AVG number become less than 0 (zero), then a minus (-) sign will be to the left of the number to signify it is negative.

3. 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.

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

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4. SBFY1112, Agriculture Engine Fuel Specifications.

Used for 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.

Example: 1. The diesel fuel measures 37° API and 90°F temperature using the 1P-7408 Thermo-hydrometer. The chart in the instruction gives a corrected API gravity of 35.

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

5. 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.

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

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

Multiple Display Operation

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) or Corrected Specific Fuel Consumption (CSFC) of the engine.

If two displays, 154-8106 and/or 154-8105, are connected to the junction box using 154-8095 Cables, only one can be allowed to communicate with the 168-7745 flowmeters or the two display’s will interfere with each other trying to communicate. The display allowed to communicate with the flowmeters to acquire fuel data is called the "Master" and the other display must be setup to receive fuel data from the "Master" display, so it is referred to as the "Slave". To setup a display as "Master" or "Slave" go to the Main Menu from the Normal Display Mode by pressing MENU. Use the scroll up or down switch until the cursor is on the line showing "COMM MODE:" followed by "MASTER" or "SLAVE". Use the ENTER switch to toggle from MASTER to SLAVE or vice versa. If the ENTER switch is pressed and "ERR: LOGGING ACTIVE" momentarily is shown on this line, then Logging is ON and must be turned OFF (refer to Data Logging Sub-Menu section).

The BSFC value (term) is for engines built before approximately December 1983. The microfiche libraries SBFY1106 (12/83), Current Vehicular Engines and SBFY1107 (12/83), Current Gas, On Highway Truck and Agriculture Engines use the term Brake Specific Fuel Consumption (BSFC).

The CSFC value (term) is for engines built after approximately December 1983.

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

The SBFY1108, Fuel Setting and Related Information microfiche libraries (include): 1. 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.

Now the displays may be programmed with the flowmeter address(es) to display that particular flowmeter(s) fuel parameters (refer to the "Measuring Fuel Flow" section). Note that the "MASTER" and "SLAVE" can be programmed with different flowmeter address(es).

2. SBFY1110, Industrial Engine Fuel Specifications. Used for 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.

The Master/Slave arrangement allows the user to have remote displays, multiple data loggers to log different data at different logging rates simultaneously, or to perform the same log with both displays so there is a "backup". Note that if the Master display fails to communicate with the Slave display, then the Slave display will "promote" itself to Master and communicate directly with only the flowmeters that have their flowmeter addresses programmed in the Slave display.

3. SFBY1111, Marine Engine Fuel Specifications; propulsion only. Use the Industrial Engine Fuel Specifications library for information on power generation in marine applications.

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Programming the Function Switches (F1, F2, F3, F4, F5)

Display Factory Reset While in the Normal Display Mode, which is the same mode that the display is in after power-up, press and hold the CTRL switch and press the RESET switch until the screen changes to:

When one of the five function switches is pressed, the display will go blank (if the switch pressed was not previously programmed).

To program:

Display Screen

Options

1. Use the scroll up ↑ or scroll down ↓ switch to place the cursor on the line to be programmed or reprogrammed (line 1-4).

FACTORY RESET ARE YOU SURE?

2. Press the ENTER switch to scroll forwards through the list of available data display items.

Holding the SHIFT switch in the pressed position and pushing the ENTER switch will allow scrolling backwards.

The user is given a chance to abort the reset at that point. If the factory reset is continued, then the display is changed to its factory default condition:

F1-YES

F5-NO

1. Flowmeter’s addresses are changed to "00000".

3. Stop scrolling when the line the cursor is on shows the desired data display item.

2. Units of measure reset to Non-SI (English).

4. Repeat Steps 1 through 3 until data display items are changed or added on each display line(s).

3. Function Switch functions are blanked (F1, F2, F3, F4, and F5).

4. Data Logging Default Settings:

5. To save the new display setup, first enter the Menu Mode by pushing the MENU switch.

Stop the TOTALIZER if it shows it is started, and scroll to the line showing the function switch to be programmed. Then push the ENTER switch to save. If the display setup is being changed, then (USED) will continue to be shown on the right side of the line. If the function switch was previously not programmed, then (USED) will be shown only after the ENTER switch is pressed.

a. Data Logging setups and logging memory will be cleared. b. Logging interval = 10 minutes. c. Logging interval units = minutes. d. Logging parameters: NONE. e. Dump format = tab separated variable (TSV).

NOTE: Pressing any switch other than what is described in Steps 1-5, before the display’s function setup is saved, will result in that temporary setup being lost.

f. Logging = OFF. 5. All other setups are reset.

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Display Data Items for the Function Switches Most of the data display items are the same as pressing the specific front panel switch on the 154-8106 or 154-8105 Display, but the function keys allow selecting what may be displayed on the screen line-by-line. Below is the list of the data display items available (shown in the order seen when scrolling forward while programming): Display

Definition

ENG1 SUP

Engine 1 supply flowrate.

ENG1 RET

Engine 1 return flowrate.

ENG1 BURN

Engine 1 burn flowrate.

ENG2 SUP

Engine 2 supply flowrate.

ENG2 RET

Engine 2 return flowrate.

ENG2 BURN

Engine 2 burn flowrate.

ENG1 AVG

Engine 1 average burn rate since last reset (See note).

E1A TIME

Engine 1 average time. This is the amount of time over which the average burn rate was accumulated.

ENG2 AVG

Engine 2 average burn rate since last reset (See note).

E2A TIME

Engine 2 average time. This is the amount of time over which the average burn rate was accumulated.

ENG1 TOT

Engine 1 totalizer. Accumulates the burn rate since last reset (See note).

E1T TIME

Engine 1 total time. The time over which the burn total was accumulated.

ENG2 TOT

Engine 2 totalizer. Accumulates the burn rate since last reset.

E2T TIME

Engine 2 total time. The time over which the burn total was accumulated.

G.TOT ENG1

Grand total burn rate for engine 1. This is another totalizer for engine 1. It has no associated timer, and must be cleared from within the main menu.

G.TOT ENG2

Grand total burn rate for engine 2. This is another totalizer for engine 2. It has no associated timer, and must be cleared from within the main menu.

Display

Definition

S1

R1

Shows both supply (S1) and return (R1) temperatures for engine 1 on a single display line for convenience.

S2

R2

Shows both supply (S2) and return (R2) temperatures for engine 2 on a single display line for convenience.

E1S TEMP

Engine 1 supply temperature.

E1R TEMP

Engine 1 return temperature.

E2S TEMP

Engine 2 supply temperature.

E2R TEMP

Engine 2 return temperature.

STOPWATCH

Count-up timer in hours:minutes:seconds up to 999 hours. Can be reset by placing the cursor on its display line in normal display mode and then pressing the SHIFT and RESET switches at the same time. This item cannot be tagged for logging.

CLOCK

24 hour real-time clock. The real-time clock/calendar is powered by a lithium battery and continues to operate whether the display is powered or not.

This item cannot be tagged for logging.

The date and time are automatically saved with each log entry.

LOG END

This item is not actually a data item, but an indicator of logging progress. This item displays the number of hours remaining until the end of logging memory is reached. When logging is active (on), this display item will alternate between showing "LOG END XXXXX.XXHRS" and "LOG EVERY XXXX.XXMIN". The "LOG EVERY..." shows how often data is logged to memory and only appears when logging is active. This item cannot be tagged for logging. Blank for the display line.

Blank for the display line.

NOTE: If there is not return side flowmeter, as indicated by an all zero address field, then this data item will reflect the supply side flowmeter, only.

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Operational Modes

Main Menu

There are two general modes of operation for the fuel flow display. They are referred to as "Normal Mode" and "Menu Mode". Normal Mode is the display mode the unit starts in after power-up. This mode is used for viewing different Engine 1 and/or Engine 2 flowmeter parameters, such as burn rate and temperature. Changing which data is visible is done using the keypad switches on the front side of the display.

This menu is entered while in the Normal Display Mode by pressing the ENTER switch. Press the ENTER switch again to exit the Main Menu and return to the Normal Display Mode. The Main Menu allows the user to view and make changes to the parameters viewed in the Normal Display Mode. Use scroll up and down switches to move the flashing block-shaped cursor to the line of interest, then press the ENTER switch to initiate the action with the particular menu item (line).

The Menu Mode is entered while in the Normal Mode by pressing the MENU switch. Press the MENU switch again to exit the MENU Mode and return to the Normal Mode. The Menu Mode has several Menus:

Pressing and holding the SHIFT switch and then pressing the scroll up switch while in Menu Mode will cause the menu display to shift "up" by 4 lines in the display order, leaving the cursor positioned 4 lines "higher" than before.

Main Menu

Pressing and holding the SHIFT switch and then pressing the scroll down switch while in Menu Mode will cause the display to shift "down" by 4 lines in the display order leaving the cursor positioner 4 lines "lower" than before.

Data Logging Sub-Menu Tag Sub-Menu Arrange Sub-Menu The menus are arranged one beneath the other.

The Menu Mode’s Main Menu is the menu first entered when the MENU switch is pressed while in the Normal Mode. The Data Logging Sub-Menu is then entered by using the scroll up or scroll down switch to move the cursor to the line showing "DATA LOGGING MENU>:" and pressing ENTER switch. The Data Logging Sub-Menu is exited to the Main Menu by pressing the MENU switch. The Data Logging Sub-Menu and its two Sub-Menus (Tag and Arrange) are used for setting up, performing, and down loading a datalog. The Main Menu and all Data Logging Sub-Menus are next described in detail.

NOTE: You will not be allowed to change some menu items when either logging is active, or the totalizer is active. The display will warn you when this is the case by flashing a short message such as: "ERR: TOTALIZER ACTIVE" or something similar for a second or two.

Main Menu Items 1. TOTALIZER STARTED: Starts and stops all totalizing functions which include ENG1 TOTAL, ENG2 TOTAL, G.TOT ENG1, and G.TOT ENG2. Average burn calculations are not affected. When the cursor is on this line, press ENTER to toggle between TOTALIZER STARTED and TOTALIZER STOPPED. When power is first applied to the display, the totalizer is started automatically. Some functions, such as changing the flowmeter’s addresses is not allowed while the totalizer is running.

2. CLEAR GRAND TOTALS: When the cursor is on this line, press the ENTER switch to clear the grand totals. You will be prompted to confirm that you wish to clear the grand totals. Press F1 to confirm, or F5 to abort the action. The values of the grand totals (G. TOT ENG1 and/or G. TOT ENG2) can be viewed by programming one of the function switches (F1, F2, F3, F4, or F5).

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NOTE: Press the ENTER switch and key in the 5 digit "ADDRESS NO." located on the flowmeter’s Transmitter FuelCom Decal (Illustration 7). Keying in "00000" on a specific flowmeter address line "turns off" this flowmeter.

If a flowmeter is "turned off", then the display will not show fuel parameter data for this flowmeter while in the Normal Display Mode and instead will display "-OFF-". If "00000" is not keyed in for the flowmeter address, then it must match the "ADDRESS NO." on the flowmeter’s Transmitter FuelCom Decal.

3. SET TIME: To set the current time of the clock, move the cursor to this line and then press the ENTER switch. The cursor will move to the hours position. This is a 24 hour clock (no AM/PM). Enter a 2 digit number between 00 and 23. Press the ENTER switch again. This will move the cursor to the minutes location.

Enter a two digit number between 00 and 59, press ENTER, then do the same for the seconds. When the ENTER switch is pressed, after setting the seconds, the time will be set to that number. If you wish to leave a number unchanged, just press the ENTER switch to skip to the next field without entering any digits.

Note that the time display does not change (update) as the seconds pass. This is normal.

The display in menu mode is not updated second by second, as in Normal display mode, but only after a switch has been pressed.

11. SAVE F1: Used for saving a programmed F1 key. Refer to "Programming the Function Switches (F1, F2, F3, F4, F5)" for a more detailed explanation.

12. SAVE F2: Similar to "SAVE F1", above.

4. SET DATE mm/dd/yy: Displays the current date in MONTH/DAY/YEAR format. To change the date, press the ENTER switch, enter the two digit month, press ENTER again, enter the two digit day, press ENTER, and enter the two digit year.

13. SAVE F3: Similar to "SAVE F1", above.

14. SAVE F4: Similar to "SAVE F1", above.

15. SAVE F5: Similar to "SAVE F1", above.

16. COMM MODE: MASTER: For single display systems, this should be left in the MASTER position. The SLAVE position is used to allow more than one display to be connected to the 154-8107 Junction Box. See Multiple Display Operation section for a more detailed explanation.

NOTE: The two digit year designators ’98’, and ’99’ are interpreted as meaning 1998 and 1999, respectively. ’00’ through ’96’ are interpreted as meaning the years 2000 through 2096, respectively.

5. VOLUME UNITS: Sets volumetric units of measure to gallons or liters. After moving the cursor to this line, press ENTER to toggle between GAL or LIT. The factory default is GAL.

17. UPPER SPAN: UNUSED 18. LOWER SPAN: UNUSED

6. TEMP UNITS: Sets temperature units of measure to degrees F or degrees C. When the cursor is located on this line, press ENTER to toggle between DEG.F or DEG.C. The factory default is DEG.F.

19. DATA LOGGING MENU: Selecting this item by pressing the ENTER switch will activate the Data Logging Sub-Menu.

Data Logging Sub-Menu

7. ENG1 SUP ADR: Engine 1 supply flowmeter address (see Note).

This sub-menu is used for setting up and doing a Datalog. Select this sub-menu by going to the "DATA LOGGING MENU>:" in the Main Menu and pressing the ENTER switch. Go from the Data Logging Sub-Menu back to the Main Menu by pressing the MENU switch.

8. ENG1 RET ADR: Engine 1 return flowmeter address (see Note).

9. ENG2 SUP ADR: Engine 2 supply flowmeter address (see Note).

1. TAG ITEMS TO LOG >: Selecting this menu entry causes the display to enter and display the TAG sub-menu. The TAG sub-menu is used to select and de-select (tag/un-tag) the data items to be logged. Tagging/Un-tagging of data items is not allowed while datalogging is active. The error message "ERR: LOGGING ACTIVE" will appear momentarily if the cursor is on the "TAG ITEMS TO LOG>" line and ENTER is pressed while logging is active (ON).

10. ENG2 RET ADR: Engine 2 return flowmeter address (see Note).

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5. LOG INTRVL UNIT: This value toggles between SEC and MIN. The corresponding value in LOG INTRVL will change when this selection is changed. Note that when displaying minutes, the actual value is still in seconds, and the minute value displayed is actually a rounded value. For example, if you had initially entered 110 seconds for a log interval, then changed the logging interval units from seconds to minutes, the logging interval would then display as 1 minute, however, the actual interval for logging would still be 110 seconds. If you wish to enter an integral number of minutes (for example, 10 minutes), first change the units to minutes, then enter 0010. To double check, toggle back to seconds, and the logging interval would then display 600SEC (for this example).

2. LOGGING IS: This value toggles between ON and OFF, which turns the logging on and off. If logging is turned ON (active), and power is removed from the display, then logging will resume as soon as power is re-applied to the display. The display will automatically turn logging off when the memory is full. If logging is turned ON, then OFF, and then back ON at a later time, the data logging continues from the point that it was when it was last turned off.

The data from the previous logging session in NOT lost.

3. LOG SPAN: This value displays the time (in hours) remaining in logging memory, given the current logging interval selected and the number of items currently tagged for logging.

The LOG SPAN can be viewed at anytime and decreases as a datalog is performed until it reaches 0.0 hours. At this point, the display will turn OFF the logger and "LOGGING OFF" will be shown on the logging line. If you choose to enter a value here (in hours), the display will calculate the minimum logging interval required to fill logging memory in that selected time, and will change the logging interval to the calculated minimum interval. Only an integral number of hours can be entered. For example: If the log memory is empty, two items are tagged to be logged (ENG 1 NET and ENG 1 TOTAL), and the selected log interval is 60 seconds, this value will be displayed as over 270 hours. This means that logging will stop with memory completely filled up about 11 days after being started (providing uninterrupted power is provided). If the number 168 were entered here, the logging interval would change to about 36 seconds. Then, logging would stop with memory full 168 hours (7 days) after being started.

6. CLEAR LOG MEMORY/LOG MEMORY IS EMPTY: This function is used to clear logging memory. If log memory is already cleared, the menu entry will appear as: "LOG MEMORY IS EMPTY". If the log memory contains data, the entry will appear as: "CLEAR LOG MEMORY".

If the ENTER switch is pressed, the screen will change to prompt the user with: "CLEAR LOG MEMORY?" and "ARE YOU SURE?" with "F1-YES" and "F5-NO". If the user wishes to clear log memory, the F1 switch should be pressed. If the F1 switch is pressed, the message "LOG MEMORY CLEARED" will appear momentarily, and the menu entry will change to "LOG MEMORY IS EMPTY". If the user does NOT wish to clear memory, then press the F5 switch to abort the operation, and the message "CLEAR ABORTED" will appear. If the menu entry appears as "CLEAR LOG MEMORY", then the logging memory contains data. If the menu entry appears as "LOG MEMORY EMPTY", then, of course, the log memory is empty.

4. LOG INTRVL: This value represents the time period between successive ’logs’ of data to memory. The minimum value for this item is 1 second. The maximum value is 65535 seconds (1092 minutes, 18.2 hours). The default is 10 minutes.

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7. MEMORY OVERWRITE: If memory overwrite is OFF, logging will stop when the memory is full. If memory overwrite is ON when the logging data fills up all of the available memory, the unit will "wrap" back around to the beginning of log memory, overwriting the oldest data with new data. This will continue indefinitely, or until terminated by external means, such as turning logging OFF. Note, memory must be clear before turning memory overwrite ON. If logging is active (ON), memory overwrite cannot be turned ON or OFF. Once logging is turned OFF, then memory overwrite can also be turned OFF. At this point, the tag definitions can be changed and logging continued, but not with memory overwrite. The log memory must be clear in order to engage memory overwrite. Note that when memory overwrite is ON, the indicators of remaining log memory only indicate the amount of time before the next "wrap" back to the beginning of memory.

The items available for logging are:

8. DUMP FORMAT IS: This item appears as TSV (tab separated variable) or CSV (comma separated variable) and is switched by pressing the ENTER switch with the cursor on this line. It is used to change the format of the data retrieved from log memory and dumped to a personal computer. It is either separating the variables by tabs (TSV) or commas (CSV). The default is TSV, which is compatible with most spreadsheets.

12. ENG 1 TOTAL TIME

1. ENG 1 SUPPLY 2. ENG 1 RETURN 3. ENG 1 BURN 4. ENG 2 SUPPLY 5. ENG 2 RETURN 6. ENG 2 BURN 7. ENG 1 AVG. BURN 8. ENG 1 AVG. TIME 9. ENG 2 AVG. BURN 10. ENG 2 AVG. TIME 11. ENG 1 TOTAL

13. ENG 2 TOTAL 14. ENG 2 TOTAL TIME 15. ENG 1 GRAND TOTAL 16. ENG 2 GRAND TOTAL 17. ENG 1 SUPPLY TEMP

Tag Sub-Menu

18. ENG 1 RETURN TEMP

The tag menu lists all of the data items available for logging. It is only accessible from the Data Logging Sub-Menu. Enter the Tag Sub-Menu by scrolling to "TAG ITEMS TO LOG >" and pressing the ENTER switch.

19. ENG 2 SUPPLY TEMP 20. ENG 2 RETURN TEMP

Items to be logged are "tagged" by moving the cursor to the line to the desired data item using the scroll up or down switch and then pressing the ENTER switch. This action will tag an item if it was untagged, or un-tag a previously tagged item.

Tagged items are shown by an asterisk (*) to the right of the item.

When you have finished tagging/un-tagging items to be included/excluded as data items to be logged, press the MENU switch. This will place the display in the ARRANGE Sub-Menu (refer to the ARRANGE Sub-Menu, which is the next section).

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The ordering of the data items in the Arrange Sub-Menu determines in which "column" the data item appears. For example, if you had tagged Engine 2 return, Engine 2 supply, Engine 1 supply, and then Engine 1 return (in that order), when you pressed the menu switch to enter the Arrange Sub-Menu, it would look like this:

Arrange Sub-Menu The Arrange Sub-Menu is entered by pressing the MENU switch while in the tag sub-menu.

The Arrange Sub-Menu is used to allow the user to view and change the ordering in which the data items are stored while logging. The data will be in this order when "dumped" to a computer at a later time. Initially, the ordering of the data items is the order in which they were tagged, in the Tag Sub-Menu. The Arrange Menu shows only those items that have been tagged.

ENG 2 RETURN ENG 2 SUPPLY ENG 1 SUPPLY ENG 1 RETURN And the resulting "dump", would have looked like this (from the 154-8106 Fuel Flow Display for this example):

To change the ordering of the data items, place the cursor on the data item you wish to move UP in the list, and press the ENTER switch. The data item will swap places with the data item which was above it, and the cursor will remain on the data item that was moved, allowing for multiple moves of the same data item by pressing the ENTER switch multiple times.

Unlike the other menus, the Arrange Menu is not "circular", in that, if you are at the bottom (last) menu item and attempt to move ’down’, the display does not move back to the top of the list of menu items. When you are at the top (bottom), the UP (DOWN) arrow keys will be ignored. The Arrange Sub-Menu can be exited by pressing the Menu switch, which changes the display to the Data Logging Sub-Menu.

CATERPILLAR 154-8106 FUEL FLOW DISPLAY v3 - 2.09 LOG DATA REPORT 06/18/1999 06:53:37 DATE/TIME ENG2 RETURN GPH 06/17/1999 16:54:09 06/17/1999 16:54:10 06/17/1999 16:54:11 06/17/1999 16:54:12 06/17/1999 16:54:13 06/17/1999 16:54:14

726.16 726.16 726.16 726.16 726.33 726.31

ENG2 SUPPLY GPH

ENG1 SUPPY GPH

ENG1 RETURN GPH

1087.76 1087.78 1087.80 1087.80 1087.94 1088.01

1088.20 1088.29 1088.38 1088.38 1088.40 1088.37

727.13 727.18 727.25 727.25 727.32 727.34 0697-10

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Data Logging Operation

Performing a Datalog

The 154-8106 and 154-8105 Fuel Flow Displays have the ability to record (log) information at user specified intervals into its memory. This information can be later retrieved using a personal computer. The information is pre-formatted into row/column type of format suitable for importation into a spreadsheet or database program.

1. First refer to Measuring Fuel Flow in the Operating Instructions section to setup the display and system connection.

2. Data logging functions are done while in the Data Logging Sub-Menu. Refer to the Operational Modes section. Next "tag" the data items desired to be logged in memory. Enter the Tag Sub-Menu through the Data Logging Sub-Menu.

NOTE: Contact CSTG for more information and the components necessary to download the datalog from a Fuel Flow Display to a personal computer.

3. Clear the log memory, if desired, by going to the Data Logging Sub-Menu, scrolling up or down to the CLEAR LOG MEMORY line and pressing the ENTER switch and when prompted pressing the F1 switch. If the line shows LOG MEMORY IS EMPTY, then the log memory is already cleared. If the log memory is not cleared and a log is performed, then the logged data will be stored in memory just after the data of the last logged data.

General Codes ERR: LOGGING ACTIVE

This message appears when the user tries to change items that are disallowed during logging (LOGGING ON), such as attempting to clear log memory, or trying to change which items are tagged for logging. This message will appear on the display’s bottom line.

ERR: OVERWRITE ON

This message appears if the user attempts to change the logging tag definitions when overwrite is on, and there is existing data in the log memory. This message will appear on the display’s bottom line.

-9999.99

This number will be logged in place of a number to indicate that the entry is invalid.

The invalid data may be the result of the display not communicating with flowmeter, which can be caused by an incorrect flowmeter "ADDRESS NO." keyed into the display or a defective cable.

4. Select the Logging Interval (LOG INTRVL), which is how often the user desires the "tagged" data items to be recorded in memory.

Changing the value of the LOG SPAN, LOG INTRVL, or logging interval unit (LOG INTRVL UNIT) will change the value of the other two if the display’s memory would fill before completing the requested datalog (depends on if Loggers Memory was filled, the number of "tagged" data items, the sampling rate (LOG INTRVL and LOG INTRVL UNIT), and the length of logging (LOG SPAN).

5. To clear the Grand Total(s) enter the Main Menu. Scroll up or down to the display’s CLEAR GRAND TOTALS line. Press the ENTER switch and when prompted press the F1 switch.

The display’s line will still show CLEAR GRAND TOTALS even after clearing the grand totals.

The value(s) of the Grand total(s) can only be viewed by "tagging" the grand total(s), performing a datalog, and then downloading the datalog.

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NOTE: If logging is turned ON, but no data items have been "tagged", then the logging will be turned OFF (display’s line will change from LOGGING ON to LOGGING OFF when the cursor is moved from this line, the display is turned off and then turned back on, or the MENU switch is pressed).

6. While still in the Data Logging Sub-Menu, scroll up or down to the display line showing MEMORY OVERWRITE. Toggle between memory overwrite OFF or ON by pressing the ENTER switch. If it is OFF, then the datalogger will automatically stop logging when memory is full. The logger may be stopped manually at any time by pressing the ENTER switch on the display line showing LOGGING OFF. If the MEMORY OVERWRITE is ON, when the LOG SPAN reaches 0.00 (log memory is full) the datalogging will continue and the LOG SPAN will be reset back to its initial state when it started the log. This will continue indefinitely and the logging is terminated manually.

Downloading the Logged Data A personal computer with an available RS232 or RS485 port is necessary to download the logged data. An RS485 to RS232 converter will be required if only an RS232 port is available on the personal computer). Any device used to capture the data must be capable of accepting continuous data at 19,200 baud to a total of approximately one megabyte. Contact CSTG for information on how to interface the Fuel Flow Display and personal computer in order to download the datalogged information. The data logged, which is stored inside of the display is not cleared after a download and will be retained even if power is removed to the display.

NOTE: Memory must be cleared before MEMORY OVERWRITE can be turned ON. 7. Scroll up or down to the display’s DUMP FORMAT IS line. Toggle between TSV (tab separated variable) and CSV (comma separated variable) using the ENTER switch.

"DUMP FORMAT IS" changes the format of the data retrieved from log memory and dumped to a personal computer. It is either separating the variables by tabs (TSV) or commas (SCV). The default is TSV, which is compatible with most spreadsheets.

1. First setup the Fuel Flow Display to download the data. Press the PRINT switch on the display’s keypad and the display will show "PRINT LOG DATA NOW?" and the prompts to press F1 for YES and F2 for NO. Do not push any other switch pads and setup the personal computer to accept the logged file.

NOTE: The dump format can be changed after logging has been turned ON or when it is finished and the logging is turned OFF. 8. The Fuel Flow Display is now setup for Data Logging. Turn on the logger by going to the LOGGING OFF line in the Data Logging Sub-Menu and pushing the ENTER switch.

Logging with start and the displays line will change to show LOGGING ON (note).

9. Press the MENU switch to go to the Main Menu.

Scroll up or down to the display line showing TOTALIZER STOPPED and press the ENTER switch to restart the totalizer (display’s line will now show TOTALIZER STARTED).

10. Reset the Average(s) and Total(s) now, if desired.

11. Power to the Fuel Flow Display may be removed and the logged data in memory will be preserved (memory is battery backed).

The datalogging setup will remain the same until a new setup is programmed into the display and is retained even if power is removed from the display.

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8. Watch the transfer of the logged data scroll by on the personal computer’s display. The transfer is complete when "END-OF-DATA" is seen on the display in real time. Select "Transfer" on the HyperTerminal’s menu bar, select sub menu item "Capture", and then select sub-menu item "Stop" to stop the data capture (delaying the manual termination of the of the download will increase the amount of extraneous characters stored at the end of the data file).

NOTE: The Fuel Flow Display’s data logger does not have to be turned off (LOGGING OFF) while downloading to a personal computer.

Logging will be suspended automatically while the Fuel Flow Display downloads data to the personal computer and then resumes when the download is complete.

2. Setup the personal computer to accept the data to be downloaded from the Fuel Flow Display. For a personal computer running Windows95, the "HyperTerminal" program will be utilized to capture the data file from the Fuel Flow Display and then store it. The next instructions are when using the "HyperTerminal" program in Windows95.

9. The information stored inside of the display is not cleared after a download. The information is now also stored in the personal computer in an ASCII text file and ready for importation into a spreadsheet or can be sent directly to a printer. Note that because of tab settings, it is likely that the column headers will be misplaced slightly if you send it directly to a printer (note). The column headings will be in the proper position if imported into a spreadsheet. Tab settings may be adjusted inside a word processor and many text editors. Any extraneous characters at the end of the data file may be deleted while in a spreadsheet or word processor.

3. Open the "HyperTerminal" program by using the "Windows95 Start...Programs...

Accessories...HyperTerminal...HyperTerminal" menu sequence.

4. If not already setup, setup the HyperTerminal by selecting whether the COM1 or COM2 port will be used to capture data on the personal computer. a. Type in "COM1 Direct" for using COM1 port or "COM2 Direct" for using COM2 port for the name of the new connection. Click on OK.

NOTE: If the format of the data is changed using a word processor or text editor the data may not import into a spreadsheet correctly, and will require adjustment there. If the user wants to print out the data, then it is recommended to import the data file to a spreadsheet and then print it out.

b. Click on the down arrow to the right of "Connect Using" and choose "Direct to Com1" or "Direct to Com2" depending on whether using the COM1 or COM2 port. c. Choose "19200" for "Bits per Second", "8" for "Data Bits", "None" for "Parity", "1" for "Stop bits", and "None" for "Flow Control".

Click on OK to save this setup.

5. Select the "Call" pull down window and then select "Disconnect" to reset capture before transferring the data file.

6. Select "Transfer" on the HyperTerminal’s menu bar and then select sub-menu item "Capture Text...". The HyperTerminal will respond by offering the default filename of CAPTURE.TEXT. You can accept this default or choose your own filename and directory location. Click on OK when ready to capture the data file. The HyperTerminal program is now waiting for the data file from the Fuel Flow Display.

7. Press the F1 switch on the Fuel Flow Display, which will start the transmission of the formatted ASCII data to the personal computer.

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Troubleshooting Most flowmeter operation problems can be solved by carefully reviewing this manual. Some specific problems are listed below. Review all of the possible causes and solutions, since some difficulties are caused by a combination of problems and may required multiple solutions.

Operating the flowmeter with liquids or conditions other than those specified can reduce its accuracy, can damage the flowmeter, and may void your warranty.

Before disassembling the flowmeter, depressurize any of the lines connected to the meter. A small amount of fuel will remain in the flowmeter and will leak out when it is opened.

Take any precautions necessary to deal with this fuel. Failure to heed this warning may result in serious bodily injury.

Consult CSTG BEFORE changing operation conditions.

Fuel Flow Measurement System Troubleshooting Chart Problem Flow is restricted.

Fluid flowing, but there is no output signal (WARNING: COMM LOST shows on the display’s bottom line).

LOST! will be displayed on the display’s line of the flowmeter that output signal is not seen.

Possible Cause

Possible Solutions

Inlet flow straightener is clogged.

Debris may be caught in the flow straightener. If so, disconnect inlet and remove debris. Also, if a filter for the flowmeter is located upstream, make sure it is an appropriate size.

Pressure drop across flowmeter is too high.

Flowmeter size may need to be increased. Make sure the supply and return line flows are within the flowmeter’s calibrated range.

Bent gear shafts.

Meter must be replaced.

Flowmeter not connected or cable is defective.

Connect flowmeter to junction box (one of ports 1-6).

Replace cable.

Transmitter is not screwed Unscrew the transmitter and make sure the opening in the cover plate for the into the flowmeter properly. transmitter is clear of any dirt and debris. Screw the transmitter back in. FINGER TIGHTEN ONLY; over tightening can damage the transmitter and/or flowmeter’s body.

Transmitter is malfunctioning.

Improper wiring or extreme temperatures can damage the transmitter. The flowmeter’s transmitter and body are calibrated as a unit and must be recalibrated as a unit if either fails.

Gears installed backwards. Make sure the gears are oriented properly. The "X" gear’s imbedded magnets must be facing the transmitter side of the flowmeter. The X and O marks are on the SAME side of the gears as the magnets. See Illustration 30.

Flowmeter is giving inaccurate readings.

Flow rate is not steady through the flowmeter.

Gears are jammed.

Debris may be caught in the gears. If so, open the flowmeter and remove it. Also, make sure that an appropriately sized filter is located upstream from the flowmeter. Make sure that the ball bearings spin freely. Jammed bearings may also cause the gears to jam.

Flow rate is too low.

Increase flow rate or check to see if the fluid application has changed. If the application has changed.

Transmitter wire is receiving interference.

Interference can be caused by other electrical devices placed too close to the transmitter cable or by not properly grounding the sensor.

Gears are dragging.

Perform the cleaning procedure for the flowmeter described in the Maintenance section. Gear centering shims may not be installed. Jammed or worn ball bearings may also cause the gears to drag.

Flowmeter outlet is not pressurized.

Pressurize the downstream side of the flowmeter or lengthen the amount of piping between the flowmeter and the pipe outlet.

Flow rate is too low.

Flowmeter gear(s) dragging.

Problem with engine fuel system.

Air in the fuel line.

Check piping system for possible sources of air and remove. If needed, install air-eliminator. Even micro-bubbles can affect the flowmeter readings.

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Fuel Flow Measurement System Troubleshooting Chart (Continued) Problem Display’s screen is blank.

Possible Cause No power applied to display.

Possible Solutions Power supply is turned OFF. Defective cable or connection from power supply and/or display to junction box.

Defective fuse in 8T-9280 Power Supply.

---- shows on display.

WARNING: UNDERFLOW shows on display.

Indicates flowmeter could not calculate good data.

Defective data or defective flowmeter.

Indicates flow through flowmeter is BELOW its minimum flow range.

Flow through flowmeter is too LOW.

Turn OFF power, then turn it ON again to reset display and flowmeters.

Flowmeter is too LARGE for fuel system.

Plugged fuel system.

Transfer pump defective.

Flowmeter gear(s) dragging,

WARNING: OVERFLOW shows on display.

Indicates flow through flowmeter is ABOVE its maximum flow range.

Supply flow rate is Incorrect measurement of LOWER than expected. fuel flow rate, or actual flow is LOWER.

Flow through flowmeter is too HIGH.

Problem with engine fuel system.

Defective fuel transfer pump.

Air in fuel.

Flowmeter gear(s) dragging.

Supply flow rate is HIGHER than expected.

Incorrect measurement of fuel flow rate, or actual flow is HIGHER.

Problem with engine fuel system.

Air in fuel.

Flowmeter installed after a Piston-Type fuel transfer pump.

Return flow rate is Incorrect measurement of LOWER than expected. fuel flow rate or actual return flow rate is LOWER.

Problem with engine fuel system.

Air in fuel.

Flowmeter gear(s) dragging.

Meter does not remain completely filled during operation.

Low back pressure. Make sure back pressure (5 psi min.) is maintained on the outlet side of the flowmeter

Back pressure can be maintained with check valves or by locating the flowmeter away from an unpressurized opening in the piping.

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Fuel Flow Measurement System Troubleshooting Chart (Continued) Problem

Possible Cause

Possible Solutions

Return flow rate is higher than expected.

Incorrect measurement of fuel flow rate or actual return flow is HIGHER.

Problem with engine fuel system.

Supply flow rate is LOW.

Actual supply rate may be LOWER than expected or it is being incorrectly measured.

Flowmeter in supply line is reading LOWER than expected.

Burn rate is LOW.

Actual burn rate may be LOWER than expected or it is being incorrectly measured.

Flowmeter in supply line is reading LOW.

Air in fuel.

Incorrect measurement of fuel flow rate or actual flow rate may be LOWER.

Flowmeter in return line is reading HIGH. Incorrect measurement of fuel flow rates.

Actual rates may be either HIGHER or LOWER.

Supply flow rate is HIGH.

Burn rate is HIGH.

Burn rate is negative.

Actual supply flow rate may be HIGHER than expected or it is being incorrectly measured.

Flowmeter in supply line is reading HIGHER than expected.

Actual burn rate may be HIGHER than expected or it is being incorrectly measured.

Flowmeter in supply line is reading HIGH.

Flowmeters are not measuring actual fuel flow correctly.

Flowmeter cables to monitor are reversed.

Incorrect measurement of supply fuel flow rate.

Actual fuel rate may be HIGHER.

Flowmeter in return line is reading LOW. Incorrect measurement of fuel flow rates.

Actual rates may be either HIGHER or LOWER.

Flowmeter in supply line is reading LOW. Flowmeter in return line is reading HIGH. Incorrect measurement of fuel flow rates.

Actual rates may be either HIGHER or LOWER.

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

Maintenance Internal Fuse Test/Replacement

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

2. DO NOT apply pressure air through the flowmeters, or damage to the gear’s bearings may result.

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

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

5. Use an approved cleaning solution as described in "Cleaning the Flowmeters" section.

Illustration 25. Fuse Removal.

6. NEVER permit dirt or contamination to enter the flowmeters.

1. If the 154-8106 or 154-8105 Fuel Flow Display will not operate when power is applied using the 8T-9280 (through the junction box), then test the fuse (1) located on the front of the 8T-9280 Power Supply.

Cleaning FuelCom Flowmeters This cleaning process is recommended if the end caps have been left off for an extended period of time or the gears seem to be dragging.

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

NOTE: Use the Caterpillar 1U-5499 Lubricant to clean and lubricate the meters. If this lubricant is not available, or is not successful, contact the Caterpillar Service Technology Group for any additional, approved cleaning solutions.

3. Use a 6V-7070 Digital Multimeter to test the fuses. a. Set the multimeter on the 200 Ohm scale to check the continuity between the two legs of the fuse.

NOTICE If an unapproved solvent is used to clean the meters and the sight glass is also cleaned, the sight glass may become cloudy or brittle, and crack.

b. If the fuse is good (reusable) the resistance will be less than 1 Ohm. c. A defective fuse will measure infinite Ohms (OL on the multimeter display) and should be replaced.

This will cause fuel to leak when the sight glass is in use.

d. If the fuse is defective, install a 4 AMP 3AG 250 Volt SLO BLO Fuse as a replacement.

The little fuse type no. is 313004.

FuelCom Flowmeters

To clean the meters:

To maintain accuracy of the FuelCom fuel flowmeters, maintenance must be done correctly each time a test is completed and the flowmeters are taken off the engine. Cleaning the meters must also be done when necessary.

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

2. Spray or pour the cleaning solvent into the meter.

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

4. Install a cap on the open end of the meter.

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5. Shake the meter back and forth so the cleaning solution runs from one end to the other, and past the meter’s gears.

7. Install the end cap.

NOTICE Do not permit the cleaning solution to enter the sight glass when soaking the meters. It is recommended to remove the sight glass from the flowmeter before soaking. The sight glass may become discolored.

Check for Debris or Other Contamination

3. After soaking, if the gears are still dragging, repeat this procedure until the gears turn freely.

1. Remove the end caps. Disassemble the flowmeter by following the flowmeter disassembly procedure.

4. Replace both end caps before storing the meter.

2. Examine the meter carefully for debris or any other kind of contamination.

Disassembly

6. Remove an end cap from the meter and pour out the cleaning solution.

3. Spin the gears with your finger and check for any dragging.

Before disassembling the flowmeter, depressurize any of the lines connected to the meter. A small amount of fluid will remain in the flowmeter and will leak out when it is opened. Take any precautions necessary to deal with this fluid. Failure to heed this warning may result in serious bodily injury.

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

4. If the gears do not spin freely and seem to drag, then perform the "Remove Varnish from Bearing" procedure.

5. If the gears spin freely and continue to spin for a short time, the meter can be considered as being clean.

1. Unscrew and unplug the sensor cable from the sensor.

6. After inspection is complete, reassemble the flowmeter using the reassembly procedure.

2. Unscrew the transmitter from the flowmeter. Do NOT drop the transmitter or it may be damaged. Do not allow any debris to get on transmitter’s threaded end or in the port of the flowmeter’s body. Refer to Illustration 23.

7. Install the end caps.

Remove Varnish From Bearings Varnish build-up 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.

NOTE: Each flowmeter has a "matched" transmitter and the two are calibrated as a set.

They are NOT interchangeable. The transmitter’s FuelCom label includes the meter S/N of its matched flowmeter’s body and the nameplate on the flowmeter’s body shows the same meter S/N. Refer to Illustration 8.

Use the 1U-5499 Lubricant to clean and lubricate the meters. If this lubricant is not available, or is not successful, contact the Caterpillar Service Technology Group for any additional, approved cleaning solutions.

3. Holding the flowmeter’s body in place, loosen and remove the four cover bolts. Fuel may leak out; take any precautions necessary to contain the fuel. Remove the front cover and catch the case O-ring and shims if they fall out.

1. Remove the transmitter from the meter’s body.

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

NOTE: The cover can be damaged if dropped (each gear is centered by two precision shims).

4. If the case O-ring is still set in the body, remove it.

5. If the outer shims are still on the gear shafts, remove them.

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4. Insert the case o-ring into the o-ring groove in the body. Make sure the case O-ring is completely set in the groove. A lubricant, such as petroleum jelly, which is compatible with both the case O-ring material and fuel, may be used to help the case O-ring stay in the groove during assembly.

6. Carefully remove the gears by hand. Do not use any type of object to pry them out. Handle the gears carefully. They can be damaged if dropped. Catch the inner shims if they fall out.

7. Remove inner gear shims.

5. Carefully mount the front cover onto the integral body. a. Hold the case O-ring in the groove. Do not install the cover bolts until the case O-ring is in the groove or damage will occur to the case O-ring. b. Install the cover bolts and tighten to 32 to 34 N⋅m (280 to 300 in lbs). To help ensure equal tension, move around the face of the meter tightening every other bolt; then tighten the remaining bolts. Failure to correctly tighten the cover bolts can adversely affect the flowmeters accuracy.

Refer to the specification section for the correct bolt torque.

Illustration 26.

(1) Flowmeter’s Transmitter. (2) Flowmeter’s Body.

(3) Installation Hole for Transmitter. (4) Transmitter’s Threaded End.

Reassembly 1. Carefully slide the inner set of gear shims onto the shaft (one shim for each shaft).

2. Carefully slide the gears onto the gear shafts.

The gears are marked with an X and an O. a. Place the gears on the corresponding shafts, the X gear on the shaft marked with an X and the O gear on the shaft marked O. Both marks must be visible with the gears in the flowmeter’s body. b. The X and O marks on the gears are placed on a tooth and root respectively, so that the two gears can be indexed to each other.

Illustration 27.

(1) "O" mark on gear. (2) "O" mark on shaft. (3) "X" mark on gear. (4) "X" mark on shaft.

c. Ensure that the X mark on one gear meshes with the O mark on the other. Refer to Illustrations 27 and 28.

6. Screw the transmitter into the transmitter port on the cover. FINGER TIGHTEN ONLY or damage to the transmitter or flowmeter may occur.

3. Carefully put the outer set of gear shims onto the shafts (the shims are required for proper operation).

7. Attach flowmeter cable. Plug the cable into the transmitter.

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b. DEG.C (Centigrade) or DEG.F (Fahrenheit) will show following the number on the display.

Checking the Operation of the Fuel Flow Measurement System

4. Press the ENG1 switch. ENG1 SUP should be followed by 0.00, then "UNDFLOW", and repeat indefinitely signifying underflow. The display’s bottom line will flash "WARNING: UNDERFLOW" when "UNDFLOW" is shown after "ENG1 SUP." When "WARNING: UNDERFLOW" is not shown, the temperature of the fuel in Engine 1’s flowmeter is shown after S1.

Use the following procedure to check the operation of the entire Caterpillar FuelCom Fuel Flow Measurement System. This check should be done on new equipment prior to taking it into the field.

This check will verify the proper operation of both the flow monitor and flowmeter.

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

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

The components required for this procedure are at least one 168-7745 Flowmeter and the additional components needed for a complete monitoring system. The additional components are shown in the Components section. Do the steps that follow to perform the test.

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

1. Connect power to the Junction Box. Refer to the Power for Fuel Flow Measurement section.

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

2. Connect the fuel flow display to the junction boxes "Fuel Flow Display" port using a 154-8095 Cable.

3. After power has been applied to the 8T-9280 power supply and the display is connected, activate the POWER ON switch. The indicator should turn ON and an indication should appear on the fuel flow display.

5. To perform this test, blow air through the meter to make sure the gears are turning.

FuelCom Fuel Flowmeter Functional Test

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

The gears inside the flowmeter must turn 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 gears turn too fast or too slow, no reading will appear. With practice, however, this method can be used to test flowmeters.

1. Use a 154-8095 Cable to connect a 168-7745 flowmeter to one of the junction box’s ports 1 through 6.

2. Setup the display so the flowmeter is Engine 1’s supply flowmeter (ENG1 SUP) and Engine 1’s return flowmeter (ENG1 RET) and Engine 2 are "--OFF--". Refer to Measuring Fuel Flow in the Operating Instructions section.

a. First, blow into the inlet fitting of the flowmeter.

3. Press the TEMP switch.

b. You should be able to hear the gears turn and then come to a stop after a short period of time.

a. If the flowmeter has been connected at least 15 seconds, then the temperature of the flowmeter will show on the display line showing E1S TEMP (Engine 1 supply flowmeter). This temperature reading will gradually rise from self heating if no fuel is flowing through the flowmeter to cool it.

c. When the gears turn, they will make a soft whining noise.

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9. Check the burn average (See Note).

d. Blow through the flowmeter continuously for 15 seconds, just hard enough to keep the gears turning. It is possible to get a reading on the display that will indicate if the flowmeter is operating. This is ONLY a functional check, however, an actual fuel flow test is the only way to check the accuracy of the flowmeter.

a. Press the AVG switch and ENG1 AVG will be shown on the display’s top line with the burn average value after it. b. If the gears in the flowmeter are not turning or turning to slow, then "WARNING: UNDERFLOW" will flash repeatedly on the displays bottom line to indicate the flowmeter is underflow.

6. If the gears do not turn, the flowmeter may need cleaning. Refer to the Maintenance section in this manual for cleaning information.

c. Turning the flowmeter’s gears now, as described earlier, will make the burn average increase slowly.

7. The overflow warning can be checked by blowing into the flowmeter with the display reading the supply rate as in Step 4, and then blowing harder into the flowmeter until the display’s top line shows ENG1 SUP followed by the flow number, then "OVRFLOW", and repeat indefinitely signifying underflow. The display’s bottom line will flash "WARNING: OVERFLOW" when "OVRFLOW" is shown after ENG1 SUP. When "WARNING: OVERFLOW" is not shown, the temperature of the fuel in Engine 1’s flowmeter is shown after S1. The flow number displayed is not necessarily accurate because the flow is outside of the flowmeter’s calibration range.

d. The burn average number may be 0 (zero) if you did not get readings to appear by turning the flowmeter gears in earlier steps.

If you were able to get a reading to appear on the display, then burn total number will be greater than 0 (zero). e. LPH (for Liters for Hour) or GPH (for Gallons per Hour) will be displayed after the burn average number. f. Clear the burn average memory by using the scroll up or down switch to place the cursor on the ENG1 AVG line. Then press and hold the SHIFT and press the RESET switch.

8. Check the burn total (See Note.) a. Press the TOTAL switch and ENG1 TOTAL will be shown on the display’s top line with the burn total value after it.

g. After pressing both switches, the display should read 0.00 for the burn average.

b. If the flowmeter gears are not turning or turning too slow, then WARNING: UNDERFLOW will flash repeatedly on the display’s bottom line to indicate the flowmeter underflow condition.

After all tests are completed, install the end caps on the flowmeter.

The previous steps can be used over at any time to check another flowmeter, if all the tests were successful. Continue with the steps that follow for checking two flowmeters at the same time.

c. Turning the flowmeter’s gears now, as described earlier, will make the burn value increase slowly.

NOTE: This data display item represents the supply flowmeter only because the display is not setup with a return flowmeter.

d. The burn total number may be 0 (zero) if you did not get readings to appear by turning the flowmeter gears in earlier steps.

If you were able to get a reading to appear on the display, then burn total number will be greater than 0 (zero).

Two FuelCom Fuel Flowmeter Functional Test

e. LIT (for Liters) or GAL (for Gallons) will be displayed after the burn rate number.

1. With a 168-7745 Flowmeter connected to the junction box from the previous tests, connect the second 168-7745 Flowmeter using a 154-8095 Cable to one of the junction box’s ports 1 through 6 that is available.

f. Clear the burn total memory by using the scroll up or down switch to place the cursor on the ENG1 TOT line. Then press and hold the SHIFT and press the RESET switch.

2. Setup the display so the second flowmeter is Engine 1’s return flowmeter (ENG1 RET).

Refer to Measuring Fuel Flow in the Operating Instructions section.

g. After pressing both switches, the display should read 0.00.

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e. The burn rate will be approximately 0 (zero).

The readings will NOT be exact, because the flowmeter’s accuracy within its flow range is ± 0.5% of reading per flowmeter (see the Specifications section for more information). It does, however, provide a functional check.

3. Press the TEMP switch. a. If the flowmeters have been connected at least 15 seconds, then temperature of the flowmeters will show on the display line showing E1S TEMP (Engine 1 supply flowmeter) and E1R TEMP (Engine 1 return flowmeter). These temperature readings will gradually rise from self heating if no fuel is flowing through the flowmeters to cool them.

5. The burn total and burn average functions work basically the same as using one flowmeter.

6. Check the burn total

b. DEG.C (Centigrade) or DEG.F (Fahrenheit) will show following the number on the display.

a. Press the TOT switch and ENG1 TOT will be shown on the display’s top line with the burn total value after it.

4. Press the ENG1 switch. "ENG1 SUP" should be followed by 0.00, then "UNDFLOW", and repeat indefinitely signifying underflow. The same should be displayed on the ENG1 RET line.

The display’s bottom line will flash "WARNING: UNDERFLOW" when "UNDFLOW" is shown after ENG1 SUP and also ENG1 RET. When "WARNING: UNDERFLOW" is not shown, the temperature of the Engine 1 supply flowmeter is shown after S1 and the temperature of the Engine 1 return flowmeter is shown after R1.

b. If the gears in the flowmeter are not turning or turning to slow, then "WARNING: UNDERFLOW" will flash repeatedly on the display’s bottom line to indicate a flowmeter underflow condition. c. Turning the flowmeter gears will make the displayed burn total value increase slowly. d. The burn average number may be 0 (zero) if you did not get readings to appear by turning the flowmeter gears in earlier steps.

If you were able to get a reading to appear on the display, then burn total number will be greater than 0 (zero).

a. If the gears of the supply flowmeter are turned as described earlier, the flow value will appear on the display. Engine 1’s burn rate (ENG1 BURN) will be the same value as the supply flowmeter (ENG1 SUP). An underflow warning will continue for the return flowmeter.

7. Check the burn average. a. Press the AVG switch and ENG1 AVG will be shown on the display’s top line with the burn average value after it.

b. Allow the supply flowmeter’s gears to stop turning. If the gears of the return flowmeter are turned as described earlier, the flow value will appear on the display. Engine 1’s burn rate (ENG1 BURN) will be the same value as the return flowmeter (ENG1 RET).

There will be a minus (-) sign before the burn rate number to indicate the burn rate is negative. An underflow warning will be seen for the supply flowmeter.

b. If the gears in the flowmeter are not turning or turning to slow, then "WARNING: UNDERFLOW" will flash repeatedly on the display’s bottom line to indicate a flowmeter underflow condition. c. Turning the flowmeter gears now, as described earlier, will make the displayed burn average increase slowly.

c. To get a burn rate reading to appear, the gears of both flowmeters must turn at the correct speed at the same time. This is very difficult to do by blowing into the flowmeters and is not recommended.

d. The burn average number may be 0 (zero) if you did not get readings to appear by turning the flowmeter gears in earlier steps.

If you were able to get a reading to appear on the display, then burn total number will be greater than 0 (zero).

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

8. This completes the check of the fuel flow measurement system. Install the end caps on the flowmeters.

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Assembly Diagram

Illustration 28. 168-7745 Flowmeter Assembly.

51

Dimensions

Illustration 29. 168-7745 Flowmeter Dimensions.

mm (in) A

B

C

D

E

F

G

M

T

R

X

Y

251 (9.90)

159 (6.25)

80 (3.15)

34 (1.35)

214 (8.43)

10 (.40)

13 (.51)

125 (4.90)

1/2-13UNC x .5 inch deep

64 (2.5)

60°

70°

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Calibration

Service

The flowmeter has been calibrated and the calibration is NIST traceable. The 168-7740 comes with a calibration certificate for each of the two 168-7745 flowmeters included. A decal on each flowmeter’s transmitter has a location to write the "In-Service Date". The decal also shows who performed the calibration and also states the recommended re-calibration date is one year after the "In-Service Date".

If the fuel flow measurement system does not operate correctly, refer to the "Fuel Flow Measurement 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 Measurement System" section in this manual.

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

If the flowmeters need calibration, contact and send it to:

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

Flowdata, Inc. 1817 Firman Drive Richardson, Texas USA 75081

Caterpillar Service Technology Group provides the user of this instrument with a one-year warranty from the date of purchase. If abuse is determined to be the reason for the failure, the warranty is declared void. Any out-of-warranty repairs will be charged to the owner. For any product support questions about your instrument, contact your Caterpillar Dealer or CSTG at:

1-800-833-2448 (Inside USA) 1-972-907-2787 1-972-907-8016 (Fax) E-Mail: "Sales@Flowdata.com"

1-800-541-8665 (Inside Illinois) 1-800-542-8665 (Outside Illinois) 1-800-523-8665 (Canada) Hotline E-Mail "CSTG" 022-849-4036 (Geneva Phone) 022-849-4929 (Geneva Fax) 36CSTG (COSA E-Mail) If the instrument, or any part of it needs repair, contact and send it to: ATS (Advanced Technology Services) 8201 North University Avenue Peoria, Illinois USA 61615 1-800-328-7287 (Inside USA) 1-309- 693-4170 E-Mail "REPAIR@ADVANCEDTECH.com"

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NOTES

54

NOTES

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For information on service tools or shop supplies contact Caterpillar Service Technology Group on: Caterpillar Service Technology 100 N.E. Adams Street Peoria, Illinois 61629-9110 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6618 (Fax) or Caterpillar Service Technology Caterpillar Overseas S. A. P.O. Box 6000 1211 Geneva 6 Switzerland +41 (22) 849 40 36 (Geneva Phone) +41 (22) 849 49 29 (Geneva Fax) 36CSTG (COSA E-Mail Address)

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NEHS0740 Printed in U.S.A.