370-8568 Bulk Fuel Filtration Group 50 GPM Flow Rate{0599, 0680, 0706, 0782, 1250, 1280} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

European Union Compliant, CE marked

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

Illustration 2	g02166423
Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Crushing hazard (foot)

Crushing hazard (hand)

Pinch point

Fire hazard

Electrical Shock - Hazard

Fire hazard

Safety Section

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills.

General Information

Introduction

Illustration 3	g02717924

The 370-8568 Bulk Fuel Filtration System is an integrated unit designed to remove particulates and water from diesel fuel. The maximum rated flow for this system is 190.0 L/min (50.19 US gpm).

The system consists of one particulate pre-filter vessel, one fuel/water separator vessel, and a slug/differential control valve mounted on a base/drip pan assembly. Inlet and outlet ball valves are included on the system. All pressure containing components are welded carbon steel or cast steel designed for use in all environments.

Pre-filter elements remove most of the solid particulate contamination. Coalescer elements and separator canisters remove water and filter the fuel. If restriction in the system (clogged filter elements or high water level) exceeds 172.0 kPa (24.95 psi), the slug control valve will close, stopping fuel flow.

Filters should be replaced and separator elements cleaned whenever differential pressure reaches 103.4 kPa (15.00 psi).

The slug valve also limits flow through the system to 190.0 L/min (50.19 US gpm) maximum.

The system is equipped with a pressure relief valve located on the filter/water separator vessel. The pressure relief valve prevents the system from being over pressurized above 1034.0 kPa (149.97 psi).

Additional Contact Information

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at:

USA: 1-800-542-8665, Option 1

International: 1-309-578-7372

Applications

The Caterpillar Bulk Fuel Filtration System is intended for use in any application where users store fuel for machines or engines. The filter unit is installed in series between the fuel pump on the fuel storage tanks and the fueling station, or fuel transport vehicle.

Note: The system does not require electrical power unless it is used in cold climates. Optional 381-9429 (120 V) or 381-9430 (220 V) electric heaters are available for cold climates where water removed from the fuel may freeze.

References

Reference Special Instruction, PEHJ0156, "CAT Bulk Fuel Filtration Systems"

Reference Special Instruction, PEHJ0671, "Bulk Fuel Filtration"

Reference Special Instruction, SEBU6250, "Caterpillar Machine Fluid Recommendations"

Specifications

Table 1

370-8568 Specifications
Specification	Dimension
Overall Base length	213.4 cm (84.02 inch)1
Overall Base Width	76.2 cm (30.00 inch)2
Overall Height	198.1 cm (77.99 inch)3
Unit Weight (Dry) Unit Weight (Wet)	589.0 kg (1298.52 lb)4 680.0 kg (1499.14 lb)4
Maximum Operating Pressure	1034.0 kPa (149.97 psi)
Differential slug Valve Operational Pressure	0 to 172 kPa (0 to 24.95 psi)
Inlet & Outlet Connections	5.1 cm (2.01 inch) ANSI B16.5
Fuel	No. 2 Diesel
Fluid Capacity (volume)	113.6 L (30.01 US gal)
1 Includes drain plug. 2 Includes mounting tabs. 3 Approximate four Shipping Weight 841.0 kg (1854.09 lb)

Nomenclature

Illustration 4	g03215076

Table 2

Nomenclature
Item	Description
(1)	Base
(2)	Inlet Port
(3)	Inlet Ball Valve
(3a)	Inlet Valve Handle (OPEN/CLOSE)
(4)	Pre-filter Vessel
(5)	Differential Pressure Gauge (2)
(6)	Pressure Relief Valve
(7)	Coalescer (Water Separator) Vessel
(8)	Sight Glass (Water Level)
(9)	Unfiltered Sample Port
(10)	Optional Heater Port
(11)	Manual Water Drain Valve (normally closed)
(12)	Water Drain Valve (normally open)
(13)	Automatic Water Drain Outlet
(14)	Water Drain Control Valve
(15)	Intermediate Sample Port
(16)	Automatic Air Release Valve (2 Qty)
(17)	Filtered Sample Port
(18)	Differential Pressure slug Valve
(19)	Water Meter
(20)	Outlet Ball Valve
(20a)	Outlet Valve Handle (OPEN/CLOSE)
(21)	Outlet Port
(22)	Base Drain Plug
(23)	Base Mounting Brackets

Operation Section

Note: Follow all applicable industry standards and all applicable governmental, environmental, and safety guidelines, practices. regulations. and mandates when installing, operating, and maintaining the bulk fuel filtration system.

Installation

1. The shipping weight of the 370-8568 Bulk Fuel Filtration System is 841.0 kg (1854.09 lb). Uncrate the unit and use a lifting device or fork lift truck with adequate capacity to move and position the bulk fuel filtration system between the fuel supply tanks and fueling station.

   Note: The bulk fuel filtration system base has channel openings for lift truck forks located at the load center of gravity.

2. Four mounting brackets (23) are attached to base (1). Use the brackets to secure the base to a level foundation.

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Illustration 5	g02717958
(23) Mounting Brackets.

3. Use approved pipe or hose (dealer supplied) to extend automatic water drain (13) outlet to a water storage container or appropriate disposal system.

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Illustration 6	g02717965
(13) Water Drain.

4. Use approved high-pressure pipe (dealer supplied) to extend 150 psi pressure relief valve (6) outlet to an inlet on the fuel reservoir or an approved fuel storage container.

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Illustration 7	g03215116
(6) 150 psi Pressure Relief Valve.

Note: All fluid and materials used with or on the bulk fuel filtration system must be handled and disposed of properly. This is important when working with fuels. Follow all Federal, State, and Local regulations on disposal of waste products.

5. Remove pre-filter vessel cover (4a) and coalescer vessel cover (7a). Inspect and make sure that filter elements are installed properly and element hold-downs are tight.

   Note: For more information on filter element service (removing and installing lids/covers), refer to the ""Maintenance" " Section in this manual.

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Illustration 8	g03215125
(4) Pre-filter Vessel. (4a) Pre-filter Vessel Cover. (7) Coalescer Vessel. (7a) Coalescer Vessel Cover.

6. Install filter vessel covers.

   1. Install pre-filter vessel cover (4a) and tighten fasteners to 81.4 N·m (60.00 lb ft).

   2. Install coalescer vessel cover (7a) and tighten bolts to 81.4 N·m (60.00 lb ft).

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Illustration 9	g03215125
(4) Pre-filter Vessel. (4a) Pre-filter Vessel Cover. (7) Coalescer Vessel. (7a) Coalescer Vessel Cover.

Note: Make sure that the filtration unit is grounded to the fuel supply system, either through metal piping or approved ground cables.

7. Use approved pipe or fuel hose (dealer supplied) to connect bulk fuel filtration system inlet (2) to the fuel supply. Make sure that the connection is tight and leak free.

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Illustration 10	g02717996
(2) Bulk Fuel Filtration System Inlet

8. Use approved pipe or fuel hose (dealer supplied) to connect bulk fuel filtration system outlet (21) to the fueling station. Make sure that the connection is tight and leak free.

Illustration 11	g02717998
(21) Bulk Fuel Filtration System Outlet

Note: For proper performance, inlet and outlet lines are to be 2 inches or larger.

Start-up Procedure

After installation is complete, perform the Start-up Procedure before dispensing fuel through the bulk fuel filtration system. Also, use this procedure after replacing filter elements, or any operation where the bulk fuel filtration system is opened.

1. OPEN inlet and outlet ball valves.

   1. Fully OPEN inlet ball valve by moving handle (3a) so the valve is aligned with the inlet pipe, as shown.

   2. Fully OPEN outlet ball valve by moving handle (20a) so the valve is aligned with the outlet pipe, as shown.

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Illustration 12	g02718000
(3a) Inlet Ball Valve Handle in OPEN Position. (20a) Outlet Ball Valve Handle in OPEN Position.

2. Turn ON the fuel supply pump at the fuel supply.

3. Vent air from pre-filter vessels (4) .

   1. Use a wrench (dealer supplied) to slowly OPEN vent valve (4b) by turning counterclockwise (CCW). Allow a small amount of fuel to flow out.

   2. Immediately CLOSE vent valve (4b) by turning clockwise (CW). This ensures the pre-filter vessel is full of fuel and air is not trapped in the system.

      Note: Coalescer vessels (7) are equipped with automatic air release valve (16). Venting does not require manual operation.

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Illustration 13	g03215136
(4) Pre-filter Vessel. (4b) Vent Valve. (7) Coalescer Vessel. (16) Automatic Air Release Valve.

Note: All fluid and materials used with or on the bulk fuel filtration system must be handled and disposed of properly. Proper handling and disposal of fuel filtration materials is important. Follow all Federal, State, and Local regulations on disposal of waste products.

4. Once air is vented out of the pre-filter vessel and vent valve (4b) is securely CLOSED, turn OFF the fuel supply pump.

5. CLOSE inlet and outlet ball valves.

   1. Fully CLOSE inlet ball valve by moving handle (3a) away from the inlet pipe, as shown.

   2. Fully CLOSE outlet ball valve by moving handle (20a) away from the outlet pipe, as shown.

Illustration 14	g02718005
(3a) Inlet Ball Valve Handle in CLOSED Position. (20a) Outlet Ball Valve Handle in CLOSED Position.

Operation

1. OPEN inlet and outlet ball valves.

   1. Fully OPEN inlet ball valve by moving handle (3a) so handle is aligned with the inlet pipe, as shown.

   2. Fully OPEN outlet ball valve by moving handle (20a) so handle is aligned with the outlet pipe, as shown.

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Illustration 15	g02718010
(3a) Inlet Ball Valve Handle in OPEN Position. (20a) Outlet Ball Valve Handle in OPEN Position.

2. Turn ON the fuel supply pump at the fuel supply.

3. Dispense fuel from fueling station.

4. Check differential pressure gauges (5) to monitor the pressure restriction of each filter vessel.

   Note: A differential reading of 103.4 kPa (15.00 psi) or above can indicate filter element replacement service is required. Refer to the ""Maintenance" " Section in this manual.

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Illustration 16	g03216928

5. When fueling is complete, turn OFF the fuel supply pump.

6. CLOSE inlet and outlet ball valves.

   1. Fully CLOSE inlet ball valve by moving handle (3a) away from the inlet pipe, as shown.

   2. Fully CLOSE outlet ball valve by moving handle (20a) away from the outlet pipe, as shown.

Illustration 17	g02718014
(3a) Inlet Ball Valve Handle in CLOSED Position. (20a) Outlet Ball Valve Handle in CLOSED Position.

Note: To ensure fuel quality, have fuel cleanliness tested on a regular basis. For more information on fuel quality testing, refer to the latest version of Special Instruction, SEBU6250, "Caterpillar Machine Fluid Recommendations".

Maintenance Section

Shutdown Procedure

Perform the Shutdown Procedure before replacing filter elements, disconnecting inlet and/or outlet lines, or making any repairs to the system.

1. Turn OFF fuel supply pump.

2. Position inlet and outlet ball valves.

   1. Fully CLOSE inlet ball valve by moving handle (3a) away from the inlet pipe, as shown.

   2. Fully OPEN outlet ball valve by moving handle (20a) so the handle is aligned with the outlet pipe, as shown.

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Illustration 18	g02718016
(3a) Inlet Ball Valve Handle in CLOSED Position. (20a) Outlet Ball Valve Handle in OPEN Position.

3. Drain approximately 114.0 L (30.12 US gal) of fuel from pre-filter and coalescer vessels by dispensing fuel into an approved tank or container.

   1. To aid fuel drain-down from pre-filter vessels (4), use a wrench (dealer supplied) to slowly OPEN vent valve (4b) by turning counterclockwise (CCW).

   2. After fuel is drained, securely CLOSE the vent valve by turning clockwise (CW).

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Illustration 19	g03215136
(4) Pre-filter Vessel. (4b) Vent Valve. (7) Coalescer Vessel. (16) Automatic Air Release Valve.

4. If the system will be moved to another reservoir or to storage, disconnect and drain inlet, outlet, and all other lines and/or hose connections.

Note: All fluid and materials used with or on the bulk fuel filtration system must be handled and disposed of properly. Proper handling and disposal of fuel filtration systems is important. Follow all Federal, State, and Local regulations on disposal of waste products.

Filter Element Replacement

Replace all filter elements whenever differential pressure reaches 103.4 kPa (15.00 psi) .

Replace Pre-filter Elements

1. Complete Steps 1 through 4 in the ""Shutdown Procedure" " section in this manual.

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NOTICE
To prevent poor filtration and/or damage to components, vessels must be drained completely, and accumulated contaminates removed annually. Completely clean out any debris from inside the vessels.

2. Remove dirty pre-filter elements.

   1. Remove eight fasteners (4c) from assembly of vessel and lid (4a). Remove prefilter vessel lid (4a) .
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   Illustration 20	g03217139
   (4a) Pre-filter Vessel Lid (4c) Fasteners (4d) Coalescer Vessel Seal

   2. The pre-filter vessel lid weighs approximately 6.4 kg (14.11 lb).
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   Illustration 21	g02558740

   3. Remove and save pre-filter element hold-down plate (4e) plus hardware.

   4. Remove pre-filter elements (4f) and discard.

      Note: Filter elements will be wet and heavy. If necessary, get help or use a lifting device with adequate capacity to remove the elements.

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   Illustration 22	g02558728

   5. Clean contaminants and debris from inside pre-filter vessels (4) annually, or as necessary to maintain cleanliness.

      Note: All fluid and materials used with or on the bulk fuel filtration system must be handled and disposed of properly. Proper disposal of fuel filtration materials is important. Follow all Federal, State, and Local regulations on disposal of waste products.

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Illustration 23	g02558732

3. Install new pre-filter element.

   1. Install new pre-filter element (4f) by lowering straight down into pre-filter vessel (4). Make sure the pre-filter element is centered on the bottom of the vessel.
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   Illustration 24	g02558740

   2. Install element hold-down plate (4e) and hardware.
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   Illustration 25	g03217139
   (4a) Pre-filter Vessel Lid (4c) Fasteners (4d) Coalescer Vessel Seal

   3. Remove and discard vessel lid seal (4d) and replace with new seal included with pre-filter element. Lubricate the seal with clean diesel fuel before installation.

   4. Install pre-filter vessel lid (4a) making sure that seal is correctly seated.

Note: The pre-filter vessel lid weighs approximately 10 kg (22 lb).

Replace Coalescer and Separator Filter Elements

1. Complete Steps 1 through 4 in the ""Shutdown Procedure" " section in this manual.

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NOTICE
To prevent poor filtration and/or damage to components, drain vessels completely and remove accumulated contaminates annually. Completely clean out any debris from inside all vessels.

2. Remove water separator canisters and coalescer elements.

   Note: Clean latex gloves should be worn when handling the coalescer and separator elements as the oils from skin can reduce the ability to function properly.

   1. Use wrenches (dealer supplied) to loosen and remove fasteners securing vessel cover (7a). Save all hardware for reuse. Use the two attached handles to remove the vessel cover and set aside.

      Note: Vessel cover weighs 27.7 kg (61.07 lb). Get help, or use an appropriate lifting device to remove cover.

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   Illustration 26	g03217237
   (7) Coalescer Vessel. (7a) Coalescer Vessel Cover.

   2. Loosen and remove nuts (7b), spacers (7c), and washer seals (7d), as shown. Save spacers, washer seals, and nuts for reuse.
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   Illustration 27	g02718083
   Nut (7b). Spacers (7c). Washer Seal (7d). (7e) Separator Canister. (7f) Coalescer Element.

   3. Coalescer elements (7f) are located inside separator canisters (7e). Remove each assembly from vessel and separate the components. It is not necessary to replace the separator canisters unless damaged or corroded.

      Note: Coalescer elements will be wet and heavy. If necessary get help, or use a lifting device with adequate capacity to remove the elements.

   4. Clean contaminants and debris from separator canisters (7e). Replace any canisters that are damaged or corroded.

   5. Clean contaminants and debris from inside coalescer vessel (7) annually, or as necessary, to maintain cleanliness.

3. Install clean water separator canisters and new coalescer elements.

   1. Place new coalescer element (7f) inside separator canister (7e) and install in coalescer vessel (7) centered over threaded rod.

   2. Install washer seal (7d), spacer (7c), and nut (7b) on each threaded rod. Tighten nut hand tight.
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   Illustration 28	g02718083
   Nut (7b). Spacers (7c). Washer Seal (7d). (7e) Separator Canister. (7f) Coalescer Element.

   3. Remove coalescer vessel seal (7g), and replace with new seal included in element replacement kit.

      Note: Make sure that seal groove is clean and free of debris before installing a new seal.

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   Illustration 29	g02718090
   (7) Coalescer Vessel. (7a) Coalescer Vessel Cover. (7g) Coalescer Vessel Seal.

   4. Install vessel cover (7a) on coalescer vessel (7) and secure with hardware removed earlier. Tighten bolts to 68.0 N·m (50.15 lb ft).

Note: Vessel cover weighs 27.7 kg (61.07 lb). Get help, or use an appropriate lifting device to install cover.

Illustration 30	g03217237
(7) Coalescer Vessel. (7a) Coalescer Vessel Cover.

Clean The Filtration System

1. For ease of operation and maintenance, clean the unit with a not solvent-based cleaner after filter replacement, or as needed.

2. Remove dirt and debris from the base after filter replacement, or as needed.

3. Base (1) features base drain plug (22). Remove the plug to drain accumulated fluids into an approved container. Reinstall the plug.

   Note: All fluid and materials used with or on the bulk fuel filtration system must be handled and disposed of properly. This is important when working with fuels. Follow all Federal, State, and Local regulations on disposal of waste products.

4. Wipe gauge lens and sight glass with a clean, dry cloth to maintain visibility.

Start up After Maintenance

Perform the Start-up Procedure after replacing filter elements, or any other maintenance where the bulk fuel filtration system is opened.

For step by step information, refer to ""Start-up Procedure" " in the ""Operation Section" " of this manual.

Slug Valve Reset

Differential fluid pressure above 172.0 kPa (24.95 psi), caused by filter element restrictions, will result in the slug valve closing, stopping all fuel flow through the bulk fuel filtration system. Before refueling can resume, do the following:

1. Turn OFF the fuel supply pump.

2. CLOSE inlet and outlet ball valves.

   1. Fully CLOSE inlet ball valve by moving handle (3a) away from the inlet pipe, as shown.

   2. Fully CLOSE outlet ball valve by moving handle (20a) away from the outlet pipe, as shown.

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Illustration 31	g02718093
(3a) Inlet Ball Valve Handle in CLOSED Position. (20a) Outlet Ball Valve Handle in CLOSED Position.

3. Check both differential pressure gauge (5) follower needles for readings above 172.0 kPa (24.95 psi) to help identify which filter is restricted.

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Illustration 32	g03216928
(5) Differential Pressure Gauges.

Note: If differential gauge readings are normal, check for high water accumulation in sight glass (8). Use manual water drain valve (11) to remove water from coalescer vessel (7). Resume refueling operation.

4. If differential pressure gauges (5) indicate restricted filters, refer to the ""Maintenance Section" " in this manual for filter element replacement procedures.

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Illustration 33	g02720879

5. Once all restrictions are corrected, reset slug valve (18) by moving lever from "TRIPPED" position to "SET" position.

Note: If slug valve (18) will not reset, or immediately closes again, refer to the ""Troubleshooting" " Section in this manual, or contact your local Cat dealer for assistance.

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NOTICE
Slug valve is factory set to 172.0 kPa (24.95 psi) differential pressure. Do NOT adjust factory setting. Changing the setting can result in improper fuel filtration and damage to bulk fuel filtration system components.

Note: To ensure fuel quality, have fuel cleanliness tested on a regular basis. For more information on fuel quality testing, refer to the latest version of Special Instruction, SEBU6250, "Caterpillar Machine Fluids Recommendations".

Service Parts

Illustration 34	g02965227

(24) Typical Pre-filter Element. (25) Typical Coalescer Element. (26) Typical Separator Canister.

Table 3

Service Parts
Item	Part No	Description	Qty
(24)	372-1034	Pre-filter Element Kit 1	1
(25)	372-1035	Coalescer Element Kit 2	1
(26)	372-1040	Separator Canister 3	1
-	381-9429	Optional Heater (120 VAC)	1
-	381-9430	Optional Heater (240 VAC)	1
1 Includes one pre-filter element and one pre-filter vessel o-ring seal. 2 Includes three coalescer elements and one coalescer vessel o-ring seal. 3 Separator canisters do not require replacement unless damaged or corroded.

Illustration 35	g03419155
370-8568 Bulk Fuel Filtration Group 50 GPM Flow Rate

Illustration 36	g03419065
370-8568 Bulk Fuel Filtration Group 50 GPM Flow Rate.

Table 4

Serviced Parts
Notes	Item	Qty	P/N	Description
-	1	1	353-3175	Valve-Pressure
-	2	1	353-3187	Meter-Water
-	3	1	353-3192	Valve-Drain
-	4	1	353-3198	Kit-Valve
-	5	1	353-3201	Valve-Control
-	6	2	353-3225	Kit-Valve
-	7	1	353-3227	Kit-Tube
A (1) D (4)	8	1	372-1034	Filter - Fuel
B (2)	9	1	372-1035	Coalescer - Water
C (3)	10	1	372-1040	Element - Separator
	11	1	388-9717	Valve As - Control
-	12	2	388-9721	Gauge-Pressure
-	13	2	388-9722	Valve - Air
-	14	1	434-4175	Seal- O-Ring

( 1 )	Filter part number is a multi unit part number consisting of one filter element and one seal for the filter vessel cover.
( 4 )	Available 399-7750 Filter - High Efficiency Pre-Filter
( 2 )	Coalescer part number is a multi unit part number consisting of three coalescer elements and one seal for the coalescer vessel cover.
( 3 )	Separator element can be cleaned by hand and reused. Replacement is only required when element is damaged.

353-3207 Seal included in 50 and 100 GPM Prefilter Kit 284-0436 (Prefilter vessel cover O-Ring)

353-3209 Seal Included in 50 GPM coalascer Kit 284-0423 (Coalescer vessel cover O-Ring)

Troubleshooting

Table 5

Troubleshooting Chart
Problem	Possible Cause	Possible Solution
No fuel flow.	Inlet or outlet valve is closed.	Fully open inlet/outlet valve.
	Fuel hose is kinked.	Straighten hose and/or provide larger hose.
	Automatic slug valve shutdown.	Check differential pressure gauge follower needles for differential pressure reading greater than 172.0 kPa (24.95 psi). The slug valve will close if filters are restricted. Change filter, elements, and reset slug valve.
		Check sight glass for high water accumulation. Wait until system purges water or drain water manually. Reset slug valve.
Differential gauge reading greater than 69.0 kPa (10.01 psi) at Start-Up.	Air in the system.	Open vent valve at top of pre-filter vessels to release trapped air.
Differential gauge reading greater than 172.0 kPa (24.95 psi).	Filter elements are restricted.	Replace filter elements and clean vessels. Reset slug valve, if necessary.

Bulk Fuel Filters and Coalescers Frequently Asked Questions

Safety

What safety hazards does this equipment pose?

• Use of a pressurized air source

Pressurized air at the nozzle should not exceed 30 psi for cleaning purposes. Protective gear covering the face, eyes, and body must be worn when using pressurized air.

• Contact with diesel fuel

Always wear protective glasses or face shield when servicing filters and other components.

• Pressurized vessel

Pressure can be trapped in the filter and/or coalescing vessels of the unit. Pressure released from these vessels can result in fuel leakage that can be hazardous. Take the following precautionary measure before opening the unit for service.

1. Stop supply pump

2. Isolate the unit by closing inlet and outlet valves

3. Open pre-filter vent valve and drain some fuel before removing the covers

• Electrical hazard

If the bulk filtration unit contains an electrical heating element 307-0655 or a 307-2569, it must be disconnected prior to any maintenance or service. Fuel flowing through the filter coalescer vessel can produce static electricity. The filtration unit must always be grounded to the fuel supply in order to avoid fire and personal injury as a result of static electricity.

• Material Safety Data Sheets

MSDS must be consulted for the chemical hazards of the fluids being used.

What is the recommended fuel supply pressure for the unit?

The bulk filter coalescer unit is capable to work with a maximum supply pressure of 150 psi. The recommended operating pressure range is 50-100 psi. If the operating pressure reaches the maximum of 150 psi, the pressure relief will open.

What precautions should be taken when servicing the equipment?

Changing filter elements is the most frequently performed maintenance procedure. To prevent fuel contamination during filter changes, it is important to do the following:

1. Supply pump is shut down.

2. Inlet and outlet gate valves are closed.

3. Unit static pressure is relieved.

4. Both primary filter and coalescer vessels are drained. Fuel drained from the bulk filter SHOULD NEVER be placed back into the filter coalescer vessel. Drain fuel should be placed back into the bulk fuel storage tank.

5. The vessel in which the filters are being changed is cleaned before new filters are installed.

Equipment Installation and Operation

What are the power requirements to energize the filter - coalescer unit?

The filter / coalescer unit requires no electrical, pneumatic, or hydraulic power for proper operation. Units that work in arctic conditions can be equipped with electrical heating elements. In this case, a continuous electrical power source must be available.

Can the equipment work out doors? Does It require constant monitoring?

The filter coalescer unit has a rugged design and is prepared to perform without any supervision under inclement weather conditions.

Does the coalescer have to be fixed on the floor?

No. The unit is contained in a drip pan welded skid, which is normally anchored in a fixed location around the fuel storing/delivery complex. The welded skid is forklift compatible and thus allows the unit to be moved to other locations. The coalescer has isolation valves. These can be closed and the unit easily hauled to a different ad-hoc location.

What is the pre-filter rating?

The pre-filter element is rate at four Microns.

What should be the ID of the supply and exit piping?

Correct operation of the unit requires that the ID of the supply lines and the ID of the discharge lines be equal to or larger than the unit supply and discharge line. Larger ID's are permitted, but not smaller ones. The 50, 100, and 200 GPM units have a supply/discharge line I.D of 2 inches and the 300 GPM unit has a line I.D. of 3 inches.

For fixed installations, welded steel piping with sweep pipe elbows is preferred. If rubber hose is used, the hose should be a minimum of 1 inch larger in diameter that the size of the pipe in the filter / coalescer unit. Hose has more resistance to flow than steel pipe and can result in a higher-pressure drop. Also, hose fittings frequently have smaller than the hose size. There should be no fitting restriction smaller than the nominal size of the inlet or outlet piping of the unit.

What is the minimum operating pressure?

The minimum operating pressure of the unit is 30 psi. 30 psi is the pressure where the slug valve starts to operate. The slug valve perform several critical functions on the unit. The slug control valve:

1) Controls maximum flow through the unit to insure filter elements are not damaged and are able to filter effectively.

2) Shuts off outlet flow if water contamination floods the coalescer and cannot be drained off fast enough.

3) Slows down flow when filters become restricted and need changing. This prevents filters from becoming completely plugged and collapsing.

What is the function of the coalsecer element and separator canister in the coalascer vessel?

The coalescer filter element attracts free water in the fuel and causes the free water to form large water droplets with sufficient mass to fall to the bottom of the coalescer vessel, where the water is drained off. However, the turbulent flow of fuel through the coalescer vessel can cause some of the small water droplets to be dislodged from the coalescer element and be suspended in the fuel. Without the separator canister, these small droplets could flow through the unit.

The separator canister complements the function of the coalescer element. The separator canister prevents the passage of the dislodged small water droplets to the fuel outlet. The separator canister consists of a fine Teflon coated wire screen. This screen is hydrophobic and repels the water droplets and prevents any water from leaving the unit. The small droplets eventually settle to the bottom of the vessel and are drained off.

Does the installation need to have a parallel bypass line/valve system?

A bypass line defeats the purpose of the coalescer unit, however some customers prefer these alternate lines in order not to disrupt fueling operations should the filter coalescing unit be under maintenance or temporarily out of commission. Provisions must be made so that these parallel bypass lines provide clean and water free fuel during filter/ coalescer downtime.

What is the water separation capability of this unit?

The coalsecer and separator canisters will remove free water to less than .01% contained in the outlet fuel. The efficiency of water removal is dependent on the amount of water in the fuel. Typically, water removal efficiency is 300 - 400 ppm.

Start-Up and Commissioning

Should the unit be purged before the supply pump is started?

Air entrapment can cause erratic operation. However, the unit has automatic air vent valves which will release the air trapped once the unit is commissioned to operate. The automatic air vent valves are located on top of the pre-filter and coalescer vessels. All units have both manual and automatic air vents. When performing the initial fill at start-up, it is better to vent the unit manually instead of relying on the auto vent. The auto vent only handles small volumes of air.

What is the recommended distance between the unit and supply pump?

There is no recommended distance between the supply pump and the unit. Experience shows that installations should provide minimal flow restriction both to and from the bulk filter unit. Steel piping with sweep elbows is the preferred piping method. The inner diameter of the piping should not be smaller that the inner diameter of the inlet port or smaller than the inner diameter of the outlet port. There should not be any sharp bends or fittings in the piping, which can cause flow restriction. Hose has more internal friction than steel pipe. If hose is used, it is recommended that the hose and all associated fittings be larger than the diameter of the pipe in the bulk fuel unit.

Illustration 37	g03419554
Iron Sweep Elbow

What would cause the unit relief valve to open?

The purpose of the relief valve is to automatically open if the system is exposed to a higher operating pressure than 150 psi. The relief valve prevents over pressurization of the unit. If the ambient temperature increases significantly, or bright sun causes the fuel in the unit to warm and expand significantly, the unit relief valve will open.

The expanding fuel trapped in the unit can cause an increase in internal pressure, which must be vented. The unit relief valve is set to open at a pressure of 150 psi.

How do we know if the slug valve is tripped?

The slug valve indicator will be shown in the "TRIPPED" position. Refer to Illustration 38.

Illustration 38	g03419553
The arrow in Illustration 38 indicates the Slug Valve in the "TRIPPED" position.

How does the Slug Valve, the Automatic Water Discharge Valve, and the Water Drain Control Valve work?

These three components are integral to the coalescer skid and work together. Water that has been separated and removed from the fuel, settles at the bottom of the coalescer vessel before it is discharged. The Water Drain Control Valve has a float mechanism that floats on the coalesced water level. The water level can be seen through a site glass located near the bottom of the coalescer vessel. The float mechanism senses the level of coalesced water inside the coalescer vessel. If the amount of water exceeds a predetermined level, the float mechanism will, automatically discharge the water through Automatic Water Discharge Valve. If water enters the coalescer vessel faster than it can be drained off, the float mechanism will rise until it trips the slug control valve. When the slug control valve closes, it shuts off fuel flow through the unit. This feature prevents contaminated fuel from leaving the bulk filtration unit.

Maintenance

How often should the filters, coalescers, and separators be replaced?

Primary filter elements remove dirt and abrasive particles from the fuel stream by trapping them in the filter media. Filter elements are changed most often. They can be changed on a regular basis or on condition. The filter has reached the end of its usable life when the differential pressure across it reaches 15 psi. Primary filter life will largely depend on two factors:

a) How contaminated is the fuel supply?

b) How much fuel is being used?

Primary filters are designed to last at least a month between changes in most applications. They should be changed every six months even if they are not plugged.

Coalescing filter elements do not plug with dirt like primary filters. Coalescing filter elements should be replaced at a minimum of at least once a year. There are a few conditions, which may result in coalescing filter elements to be changed more often:

a) The primary and coalescing vessels are not fully drained when primary filters are being changed. This permits contaminated fuel to reach the coalescing elements and may cause them to plug.

b) Primary filters elements are improperly installed and do not seal completely, or are physically damaged. Either cause can permit a flow path for dirty fuel to flow around or though the primary filter and to the coalescing elements.

c) Microbial growth in the bulk storage tank will plug both primary and coalescing elements quickly. If microbial growth is detected, the entire system must be treated chemically to kill the growth.

Separator canisters are fine wire mesh screens, which are Teflon coated. These screens are reusable and do not need to be replaced unless the screen is physically damaged. The unit contains differential pressure gauges for both the coalescer and primary filter vessels. When the differential pressures across either the primary filter or coalescer filter exceeds 15 psi, replacement of the filter element is necessary.

What regular maintenance should be performed on the unit?

Large debris and dirt trapped in the primary filter elements may fall out and over time collect in the bottom of the primary filter vessel. Both the primary and coalescer vessels should be drained, thoroughly cleaned, and inspected at least once per year.

What are the regular service items for this unit?

Refer to IRM PELJ 0671-03. This document contains all current and available serviceable parts for the four coalescer models.

How long is the warranty period for this unit?

The warranty period for the coalescer is 1 year, from the time of purchase.

Application and Specifications

Does the coalescer work if the fuel used contains bio-fuel?

The effectiveness of a coalescing element can be considerably diminished by the presence of bio-fuel. The extent to which the bio-fuel reduces water removal capability varies widely. Coalescer efficiency depends on the surface tension of the water being removed. The greater the surface tension, the more efficient is the water removal. Consider the following example of surface tension:

Take a greasy frying pan, slick with cooking oil and place the pan in a sink filled with clean water. The water has high surface tension and does not want to dissolve the grease, which forms into droplets. Now, add dishwashing soap, which is a surfactant. The surfactant properties of the soap reduce the surface tension of the water and it begins to dissolve the grease. Bio-fuels contain organic matter, which has various degrees of surfactant properties. These surfactant properties reduce the surface tension of water in the bio-diesel, causing the fuel to both absorb water and make it much more difficult to separate by the coalescer. The surfactant properties of different types and concentrations of bio-fuels can range from a minimal effect on the coalescer efficiency, to rendering the coalescer useless.

How do diesel additives affect the operation of the coalescer ?

As with bio-fuels, fuel additives can affect the efficiency of the coalescer. Some additives act as mild surfactants, and can reduce coalescer efficiency. Others contain salts, which cannot be captured by the primary filter, but are attracted to the coalescing element and can cause the coalescing element to plug. Still other additives have no apparent effect.

What are the necessary adjustments to the slug control valve?

The slug valve does not require any operational adjustments. The valve will start operation, modulating the opening, to maintain the rated flow once it senses a minimum of 20 psi of fuel flow across it.

What would trigger the slug valve to shut down?

The slug valve will shut off, stopping fuel flow through the valve in three operational instances:

• High water content in the fuel or the fuel level in the storage tank is low.

In most cases, the coalescer elements are capable of separating the water, but the drain system on the coalescer will not be able to drain the water from the coalescer vessel as quickly as it accumulates in the bottom. This will cause the water level in the bottom of the coalescer vessel to rise above normal levels. A float mechanism in the bottom of the coalescer vessel operates the automatic water drain. When the rising water level causes the float to reach an above normal position, the slug control valve is triggered and shuts downstream flow off completely. The purpose of this is to prevent contaminated fuel from reaching the vehicle downstream.

• High filter element differential pressure.

The bulk fuel filtration unit senses differential pressure across both the primary filter elements and coalescer elements. If the valve senses a high (25 psi or above) differential pressure across the pre-filter or coalescers it will shut off flow downstream to prevent the filters from collapsing and contaminated fuel from passing through the unit.

• Automatic maximum flow control.

The valve automatically modulates restricting flow to the maximum flow rating of the unit. Should this flow exceed the maximum rating, the valve will automatically restrict flow to limit it to the maximum flow rate.

Illustration 39	g03419551

Illustration 40	g03419552

Are the connecting flanges standard industrial size?

Yes, the isolation valves at the supply and discharge end of the coalescer units are the same size on each unit and are equipped with standard industrial size ANSI B16.5 Class 150 Forged Flanges. The 50, 100, and 200 GPM units have a 2" ID and the 300 GPM unit has a 3" ID. Refer to Table6 for Flange dimensions.

Illustration 41	g03419659

Table 6

Nom. Pipe Size	Flange Diameter (O.D.)	Flange Thickness (Q)	Hub Dia at Base (X)	Raised Face Dia. (F)	Hub Dia. at Welding Point (H)	Bore Diameter (B)
						Welding Neck and Socket Weld (B1)	Slip-On and Socket Weld Min. (B2)	Lap Joint Min. (B3)
1/2	3.50	0.44	1.19	1.38	.84	.62	.86	.90
3/4	3.88	0.50	1.50	1.69	1.05	.82	1.09	1.11
1	4.25	0.56	1.94	2.00	1.32	1.05	1.36	1.38
1 1/4	4.62	0.62	2.31	2.50	1.66	1.38	1.70	1.72
1 1/2	5.00	0.69	2.56	2.88	1.90	1.61	1.95	1.97
2	6.00	0.75	3.06	3.62	2.38	2.07	2.44	2.46
2 1/2	7.00	0.88	3.56	4.12	2.88	2.47	2.94	2.97
3	7.50	0.94	4.25	5.00	3.50	3.07	3.57	3.60
3 1/2	8.50	0.94	4.81	5.50	4.00	3.55	4.07	4.10

Maintenance Record

Replace filters whenever differential pressure reaches 15 psi. Clean debris from vessels annually, or as needed to maintain cleanliness.

Table 7

370-8568 Bulk Fuel Filtration Group Maintenance Record
Date	Maintenance Description	Performed By