Installation of Fuel/Water Separator{1260, 1263} Caterpillar


Installation of Fuel/Water Separator{1260, 1263}

Usage:

769C 01X


Caterpillar Products: All

Introduction

This Special Instruction outlines the installation of various fuel/water separators. These fuel/water separators utilize the 175-7060 Base As , the 177-9778 Base As , or the 225-6404 Base As .

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.

Advantages of Fuel/Water Separators

  • Improved filtration of the fuel

  • Removal of water from the system

  • Increased life of the secondary filter

Installation of filter groups with 175-7060 Base As

Use the parts in Table 1 to install a fuel/water separator that utilizes this base.

Installation of filter groups with 177-9778 Base As

Use the parts in Table 2 to install a fuel/water separator that utilizes this base.

Installation of filter groups with 225-6404 Base As

Use the parts in Table 3 to install a fuel/water separator that utilizes this base.

Necessary Parts for Installation

Table 1
Parts List for the Installation of Groups that use 175-7060 Base As    
Part Number     Description     Quantity    
207-2422 (1)     Water Separator and Fuel Filter Gp     1    
175-7060     Base As     1    
0S-1588     Bolt     2    
0T-0573     Bolt     1    
5M-2894     Hard Washer     4    
9S-8752     Full Nut     1    
( 1 ) 200-4139 Water Separator and Fuel Filter As is included in the 207-2422 Water Separator and Fuel Filter Gp .

Table 2
Parts List for the Installation of Groups that use 177-9778 Base As    
Part Number     Description     Quantity    
1R-0770 or 1R-0771     Water Separator and Fuel Filter As or Fuel Filter     1    
177-9778     Base As     1    
8T-4195     Bolt     4    
8T-4121     Hard Washer     4    

Table 3
Parts List for the Installation of Groups that use 225-6404 Base As    
Part Number     Description     Quantity    
200-4139     Water Separator and Fuel Filter As     2    
225-6404     Base As     2    
232-5991     Plate     1    
2A-4639     Bolt     8    
2K-8198     O-Ring Seal     4    
5M-2894     Hard Washer     22    
9S-8752     Full Nut     8    
3B-1915     Bolt     6    

The suggested parts that are necessary for the installation of several groups of fuel/water separators are displayed in the previous tables. Actual parts may vary according to the mounting bracket and the location.

Table 4
Flow Rates for the Filter Assemblies    
Part Number     Flow Rate    
1R-0770     430 L (114 US gal)    
1R-0771    
590 L (157 US gal)    
200-4139    
1320 L (350 US gal)    

The following procedure should be used in order to install the fuel/water separators on Caterpillar equipment. The procedures may be used with the single base arrangement or with the modular base arrangement.

------ WARNING! ------

Accidental machine starting can cause injury or death to personnel working on the machine.

To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps.

Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

----------------------

------ WARNING! ------

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Turn the disconnect switch OFF when draining and/or removing any fuel system components.

----------------------


NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.



NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


Typical Profile of Installation for 177-9778 Base As




Illustration 1g00995144

(1) 8T-4195 Bolt

(2) 8T-4121 Hard Washer

Determine the appropriate location in order to mount the fuel/water separator. Refer to Illustration 1. A template for the mounting holes is provided in Illustration 7. Use the bolts and washers in order to attach the filter base. If necessary, use other appropriate hardware in order to attach the filter base. Attach the filter base to the machine or to the mounting bracket. Refer to Table 2 for the parts list.

The mounting location for the fuel/water separator will be determined by the application. Ensure that the fuel/water separator is located in an area that can be easily serviced. Ensure that the fuel/water separator is located away from electrical components. Ensure that the fuel/water separator is located away from debris and all hot surfaces.

The diameter of the fuel hose will be determined by the application and by the fuel line from the fuel tank. The size of the fuel fittings will be determined by the application. The fuel hose should have a minimum rating of 2100 kPa (300 psi). The fuel hose must be routed away from electrical components and away from hot surfaces. The fuel hose must be routed away from rubbing and away from chafing surfaces.

Typical Profile of Installation for 175-7060 Base As




Illustration 2g00995145

(1) 0T-0573 Bolt

(2) 0S-1588 Bolt

(3) 5M-2894 Hard Washer

(4) 9S-8752 Full Nut

Determine an appropriate location in order to mount the fuel/water separator. Refer to Illustration 2. A template for the mounting holes is provided in Illustration 8. Use the suggested bolts, nuts, and washers in order to attach the filter base. If necessary, use other appropriate hardware in order to attach the filter base. Attach the filter base to the machine or to the mounting bracket. Refer to Table 1 for the parts list.

The mounting location for the fuel/water separator will be determined by the application. Ensure that the fuel/water separator is located in an area that can be easily serviced. Ensure that the fuel/water separator is located away from electrical components. Ensure that the fuel/water separator is located away from debris and all hot surfaces.

The diameter of the fuel hose will be determined by the application and by the size of the fuel line from the fuel tank. The size of the fuel fittings will be determined by the application. The fuel hose should have a minimum rating of 2100 kPa (300 psi). The fuel hose must be routed away from electrical components and away from hot surfaces. The fuel hose must be routed away from rubbing and away from chafing surfaces.

Typical Diagram of Plumbing for a Single Filter Group




Illustration 3g00995146

This illustration is effective with all of the engine models that are smaller than the 3512 Engines.

Typical Diagram of Plumbing for Multiple Single Filter Groups




Illustration 4g00995148

This illustration is effective with all of the 3512 Engines and up.

Note: Connect the fuel/water separators in parallel when two or more fuel/water separators are used.

Connecting the fuel/water separators in parallel will require two additional tee fittings. The size of these fittings will be determined by the application and by the size of the fuel line from the fuel tank.

For parallel connections, use one tee to split the fuel line from the fuel tank and divide the flow between both of the single filter groups. Use another tee to recombine the outlet lines from the individual filters before the lines reach the fuel pump.

This may also require some additional hardware that is not mentioned, including straight fittings and/or elbow fittings. These fittings will be determined by the following factors: the application and the size of the fuel line that is required by the fuel pump.

Typical Profile of Installation for 225-6404 Base As




Illustration 5g00995150

(1) 3B-1915 Bolt

(2) 5M-2984 Washer

Determine an appropriate location in order to mount the fuel/water separator. Refer to Illustration 5. A template for the mounting holes is provided in Illustration 9. Use the suggested bolts and washers in order to attach the filter base. If necessary, use other appropriate hardware in order to attach the filter base. Attach the filter base to the machine. Refer to Table 3 for the parts list.

The mounting location for the fuel/water separators will be determined by the application. Ensure that the fuel/water separators are located in an area that can be easily serviced. Ensure that the fuel/water separators are located away from electrical components. Ensure that the fuel/water separators are located away from debris and all hot surfaces.

The diameter of the fuel hose will be determined by the application and by the size of the fuel line from the fuel tank. The size of the fuel fittings will be determined by the application. The fuel hose should have a minimum rating of 2100 kPa (300 psi). The fuel hose must be routed away from electrical components and away from hot surfaces. The fuel hose must be routed away from rubbing and away from chafing surfaces.

Typical Diagrams of Plumbing for a Modular Base Filter Group




Illustration 6g00995151

This illustration is effective with all of the 3512 Engines and up.

Note: The modular base filter group may be connected by using both sides of the filter assembly (upper illustration) or by using one side of the filter assembly (lower illustration). If both sides of the filter assembly are used, the end plate will need to be modified by adding a No. 8 port. The port (1) that is next to the inlet port needs to be plugged. The port can be plugged by using a 9S-4185 Plug . Refer to the upper illustration for an example.

Mounting Template for 177-9778 Base As




Illustration 7g00995152

Mounting Template for 175-7060 Base As




Illustration 8g00995153

Mounting Template for 225-6404 Base As




Illustration 9g00995155

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