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Fuel Supply Line & Installation 13 MODULE 13: Fuel Supply Line & Installation State of Oklahoma College of the Desert West Virginia University Liquefied Petroleum MODULE 13: FUEL SUPPLY LINE & INSTALLATION Gas CONTENTS OBJECTIVES.....................................................................................................13-i INSTRUCTOR NOTES .......................................................................................13-ii TANK PLUMBING..............................................................................................13-1 FUEL LINE LAYOUT, ASSEMBLY AND INSTALLATION PROCEDURE................13-2 LINE ROUTING...............................................................................................13-2 BULKHEADS..................................................................................................13-3 FUEL LOCKS..................................................................................................13-3 MEASURING, CUTTING, AND CUSTOMIZING LINES AND FITTINGS..................13-5 FUEL SUPPLY HOSE AND FITTING INSTALLATION..........................................13-5 HOSE ASSEMBLY.............................................................................................13-7 HOSE END PREPARATION..............................................................................13-7 MANDREL TYPE HOSE END INSTALLATION....................................................13-7 PUSH-ON HOSE END INSTALLATION..............................................................13-8 REMOVING RE-USEABLE HOSE ENDS............................................................13-8 CRIMPED FERULE HOSE PREPARATION & INSTALLATION.............................13-8 INVERTED FLARE LOW-PRESSURE HOSE INSTALLATION..............................13-9 FILTER INSTALLATION...................................................................................13-10 GASOLINE (CARBURETED) LOCKOFF INSTALLATION....................................13-10 POST INSTALLATION......................................................................................13-11 TESTING THE LINES....................................................................................13-11 MODULE REVIEW ITEMS...............................................................................13-13 MRI SCORING KEY.........................................................................................13-17 ACTIVITY 13-1: HOSE & FITTING ASSEMBLY OVERHEAD TRANSPARENCY MASTERS Liquefied Petroleum Gas Training Program PAGE 13-i Liquefied Petroleum MODULE 13: FUEL SUPPLY LINE & INSTALLATION Gas OBJECTIVES At the completion of this module, the technician will be able to: • Inspect the tank valves and gauges, and discuss their characteristics and considerations per the application. • Discuss the fuel line layout and its considerations. • Properly install the fuel lines and components. • Fabricate lines and fittings. • Critique the fuel line and component installation. • Perform fuel line leak testing. Liquefied Petroleum Gas Training Program PAGE 13-ii Liquefied Petroleum MODULE 13: FUEL SUPPLY LINE & INSTALLATION Gas INSTRUCTOR NOTES INSTRUCTOR MATERIALS/MEDIA NEEDED Overhead projector or LCD panel/projection equipment Overhead transparency masters or Microsoft PowerPoint 4.0 presentation file Mod13.ppt Note: Slides correspond to text as indicated by icon VCR with TV or projection unit Laboratory Activities: Activity 13-1: Hose & Fitting Assembly Note: Lab activities correspond to text as indicated by icon STUDENT MATERIALS/MEDIA NEEDED Module 13: Fuel Supply Line & Installation MODULE REVIEW ITEMS The Module Review Items (MRI) are designed to allow for flexibility in their use. The exam may be utilized as a post-module review, pre/post test, part of a term examination, or it may be used by the student if the module is used as a self study text. OVERHEAD TRANSPARENCY MASTERS The printouts enclosed with this module are taken from the Microsoft PowerPoint 4.0 presentation file Mod13.ppt . Instructors planning to use overhead projectors should make transparencies from these printouts on a copier (or laser printer designed to safely print to acetate. Note: Please review Module 25: Training of Trainers for more hints on instructional needs and strategies. Liquefied Petroleum Gas Training Program PAGE 13-1 Liquefied Petroleum MODULE 13: FUEL SUPPLY LINE & INSTALLATION Gas TANK PLUMBING Key Points & Notes Descriptions of tank guard, fill valve, automatic stop fill, liquid level gauge, and relief valve are covered in Module 2. 13-3 Photo © Harris Fogel 13-1 Typical tank valve and gauge layout – plumbing not connected. 1. Inspect the filler valve, automatic stop fill valve, manual liquid shutoff valve, fixed liquid level gauge, relief valve, and fuel gauge 13-2 on the fuel tank. These components are installed by the tank manufacturer at the factory but should be double-checked to a s s u re correct installation, including float alignment, valve clearance, thread sealant application, component operation and orientation. 13-5 13-4 Photo © Harris Fogel 13-2 Backside of remote fill fixture. Inset Front side of remote fill fixture Liquefied Petroleum Gas Training Program PAGE 13-2 Liquefied Petroleum MODULE 13: FUEL SUPPLY LINE & INSTALLATION Gas 2. For tank installations that employ a remote fill fixture, a back- Key Points & Notes flow check valve (single or double) must be permanently installed outside the vehicle in addition to the double back-flow check valve mounted in the tank. Likewise, a #54 drill size liquid level gauge orifice fitting must be permanently mounted outside the vehicle in addition to the #54 drill size orifice fitting in the tank. 3. For tank installations that require a remote relief valve, the point of discharge must be directed upward or downward within 45o of vertical. This is intended to prevent direct discharge of propane on the vehicle or any adjacent vehicle. Further, the relief valve outlet must be protected by a rain cap or a dust cover. Refer to Figure 13-3. The valve must also have a break-away adapter at the tank opening that meets manufacturer’s specifications, with a melting point not less than 1500o F (816o C). The hose connecting the tank and remote discharge vent should be non- metallic and have an internal diameter not less than that capable of discharging the rated volume of the valve and its recommended breakaway adapter. 13-7 13-6 Photo © Harris Fogel 13-3 Relief valve remote pipe-away. Inset Rain/dust cap for relief valve pipe-away. FUEL LINE LAYOUT, ASSEMBLY AND INSTALLATION PROCEDURE LINE ROUTING Refer to the system manual. Observe how the components are laid out and interconnected. The fuel lines will usually run along the 13-8 underside of the vehicle and are fastened to the frame. The first step is to estimate the req u i r ed length for the shortest and simplest routing, including bends and anticipating conflicts. Review the planned route for the lines. Look for suitable surfaces for mounting line clamps and ties. Check the locations of planned alternations in the vehicle body. Make sure the structural integrity of the frame is not defeated with modifications to it. Liquefied Petroleum Gas Training Program PAGE 13-3 Liquefied Petroleum MODULE 13: FUEL SUPPLY LINE & INSTALLATION Gas Keep the following considerations in mind when planning. Key Points & Notes • Allow for the rotational torque of the drive train and frame flex which can shear off a tight fuel line. 13-9 • Keep the fuel lines protected by using the form of the vehicle’s frame by running the fuel line inside a channel or fold in the frame. Refer to Figure 13-4. 13-10 Photo © Harris Fogel 13-4 Liquid supply line routed and clamped along frame rail. • Make sure hoses are not kinked (use elbows and other fittings if necessary). • Keep hoses at least 8” away from hot exhaust components, or provide shielding if necessary. • Keep lines at least 3” away from spark ignition wires (electrical noise may be carried by the lines into sensitive electronic components). • Keep lines at least 3” away from moving vehicle parts. • Keep the lines at least 1” away from closed hoods and trunks. • Keep the lines from chaffing by shielding them with heat hose, springs, or coils. BULKHEADS Wherever the fuel line passes through a floor or wall panel, steel or brass sleeves or bulkhead fittings should be used to protect the line 13-11 from possible damage. Before making the first cut, verify what is on the other side of the surface. Then drill the hole and install the appropriate connector. Refer to Figure 13-5. FUEL LOCKS The following considerations should be followed when installing propane fuel locks: 13-13 1. The fuel lock should be installed according to manufacturer’s instructions. Install as close to the converter as possible so that fuel is supplied quickly to the converter during cold starts. Liquefied Petroleum Gas Training Program PAGE 13-4 Liquefied Petroleum MODULE 13: FUEL SUPPLY LINE & INSTALLATION Gas Key Points & Notes 13-12 Photo © Harris Fogel 13-5 Bulkhead fitting. 2. As mentioned in previous chapters, electric fuel locks should be installed using either a vacuum safety switch or an oil pressure switch. Refer to Figure 13-6. This ensures positive shut off when the ignition is switched off or the engine is not running. The power wire for the fuel lock should not be connected to the ignition coil, because it can rob the coil of primary voltage necessary to provide a good secondary ignition voltage spark. One volt drop in the primary circuit to the coil will cause a 5000 volt drop in secondary iginition
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