284-0415 Bulk Fuel Filtration Group 100 GPM Flow Rate{0680, 0782, 1250, 1280} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

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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

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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.

General Information Section

Introduction

Illustration 3	g02724923
284-0415 Bulk Fuel Filtration System

The 284-0415 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 378 L/min (99.9 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 ductile iron 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 (25.0 psi), the slug control valve will close, stopping fuel flow.

Filters should be replaced and separator canisters cleaned every six months, or whenever differential pressure reaches 138 kPa (20.0 psi).

The slug valve also limits flow through the system to 378 L/min (99.9 US gpm) maximum.

The system is equipped with a pressure relief valve located between the pre-filter vessel and water separator vessel. The pressure relief valve prevents the system from being over pressurized above 1034 kPa (150.0 psi).

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 tank and the fueling station, or fuel transport vehicle.

Note: The system does not require electrical power unless it is used in extremely cold climates. Optional 307-0655 electric heater (120 V) or 307-2569 electric heaters (220 V) are available for cold climates where water removed from the fuel may freeze.

References

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

Special Instruction, PELJ0671, "Bulk Fuel Filtration".

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

Specifications

Additional Contact Information

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

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

International: 1-309-578-7372

Email: dealerservicetool_hotline@cat.com

Nomenclature

Illustration 4	g02724927

Operation Section

Note: IMPORTANT: Follow all applicable industry standards, 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 284-0415 Bulk Fuel Filtration System is 753 kg (1660.0 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 tank and the fueling station.

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

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Illustration 5	g02724934
(23) Mounting Brackets.

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

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Illustration 6	g02724937
(13) Water Drain.

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 7	g02724941
(6) 150 psi Pressure Relief Valve

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.

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.

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Illustration 8	g02724943
(4) Pre-filter Vessel (4a) Pre-filter Vessel Lid (7) Coalescer Vessel (7a) Coalescer Vessel Cover

5. Remove pre-filter vessel lid (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 9	g02724945
(4) Pre-filter Vessel (4a) Pre-filter Vessel Lid (7) Coalescer Vessel (7a) Coalescer Vessel Cover

6. Install filter vessel lids/covers.

   1. Install pre-filter vessel lid (4a) and turn T-handle clockwise (CW) hand tight.

   2. Install coalescer vessel cover (7a) and tighten bolts to 68 N·m (50.2 lb ft).

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

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Illustration 10	g02724947
(2) Bulk Fuel Filtration System Inlet

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 11	g02724952
(21) Bulk Fuel Filtration System Outlet

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.

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.

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Illustration 12	g02724976
(3a) Inlet Ball Valve Handle In OPEN Position (20a) Outlet Ball Valve Handle in OPEN Position

1. OPEN inlet ball and outlet valves.

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

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

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Illustration 13	g02724979
(4) Pre-filter Vessel (4b) Vent Valve (7) Coalescer Vessel (16) Automatic Air Release Valve

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

3. Vent air from the pre-filter vessel (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 that the pre-filter vessel is full of fuel and air is not trapped in the system.

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

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.

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.
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   Illustration 14	g02724982
   (3a) Inlet Ball Valve Handle In CLOSED Position (20a) Outlet Ball Valve Handle In CLOSED Position

   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.

Operation

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Illustration 15	g02724984
(3a) Inlet Ball Valve Handle In OPEN Position (20a) Outlet Ball Valve Handle in OPEN Position

1. OPEN inlet and outlet ball valves

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

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

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

3. Dispense fuel from fueling station.

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Illustration 16	g02724985
(5) Differential Pressure Gauge

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

   Note: A differential reading of 138 kPa (20.0 psi) or above can indicate filter element replacement service is required. Refer to the ""Maintenance Section" " in this manual.

Note: Differential pressure gauges (5) are equipped with "follower needles" which will stay at the highest pressure recorded even after fuel flow has stopped. Reset the follower needles to "zero" after recording readings.

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

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Illustration 17	g02724986
(3a) Inlet Ball Valve Handle In CLOSED Position. (20a) Outlet Ball Valve Handle In CLOSED Position.

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.

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.
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   Illustration 18	g02724990
   (3a) Inlet Ball Valve Handle In CLOSED Position (20a) Outlet Ball Valve Handle In OPEN Position

   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 it is aligned with the outlet pipe, as shown.

3. Drain fuel from pre-filter and coalescer vessels by dispensing fuel into an approved tank or container.
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   Illustration 19	g02724993
   (4) Pre-filter Vessel (4b) Vent Valve (7) Coalescer Vessel (16) Automatic Air Release Valve

   1. To aid fuel drain-down from pre-filter vessel (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).

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

4. If the system will be moved to another reservoir or to storage, disconnect and drain inlet, outlet, and all other lines and 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 every six months or whenever differential pressure reaches 138 kPa (20.0 psi), whichever comes first.

Replace Pre-filter Element

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 completely drained and accumulated contaminates removed annually. Completely clean out any debris from inside the vessels.

2. Remove dirty pre-filter element.
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   Illustration 20	g02724998
   (4) Pre-filter Vessel (4a) Pre-filter Vessel Lid (4b ) Manual Air Vent Valve (4c) T-handle (4d) Vessel Lid Seal (4e) Element Hold-down Plate (4f) Pre-filter Element

   1. Turn T-handle (4c) counterclockwise (CCW) to loosen. Remove pre-filter vessel lid (4a) .

      Note: The pre-filter vessel lid weighs approximately 6.4 kg (14.11 lb).

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   Illustration 21	g02725001
   (4) Pre-filter Vessel (4a) Pre-filter Lid (4c) T-handle

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   Illustration 22	g02725004
   (4) Pre-filter Vessel (4e) Element Hold-down Plate (4f) Pre-filter Element

   2. Remove and save pre-filter element hold-down plate (4e) .
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   Illustration 23	g02725007
   (4) Pre-filter Vessel (4f) Pre-filter Element

   3. Remove pre-filter element (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 element.

   4. Clean contaminants and debris from inside the pre-filter vessel (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 handling and disposal of fuel filtration systems is important. Follow all Federal, State, and Local regulations on disposal of waste products.

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Illustration 24	g02725008
(4) Pre-filter Vessel. (4f) Pre-filter Element.

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 25	g02725009
   (4) Pre-filter Vessel. (4e) Element Hold-down Plate. (4f) Pre-filter Element.

   2. Install element hold-down plate (4e) .
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   Illustration 26	g02725013
   (4) Pre-filter Vessel (4a) Pre-filter Vessel Lid (4c) T-handle (4d) Vessel Lid 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. Turn T-handle (4c) clockwise (CW) to hand tighten and secure lid.

Note: The pre-filter vessel lid weighs approximately 6.4 kg (14.12 lb).

Replace Coalescer and Separator Filter Element

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 completely drained and accumulated contaminates removed annually. Completely clean out any debris from inside all vessels.

2. Remove water separator canisters and coalescer elements.
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   Illustration 27	g02725024
   (7) Coalescer Vessel (7a) Coalescer Vessel Cover

   1. Use wrenches (dealer supplied) to loosen and remove fasteners securing coalescer 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 42.6 kg (93.92 lb). Get help, or use an appropriate lifting device to completely remove cover.

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   Illustration 28	g02725025
   (7b) Filter Nut (7j) Bracket Nut

   2. Use a socket wrench (dealer supplied) to loosen and remove filter nuts (7b) and bracket nuts (7j). Save nuts for reuse.
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   Illustration 29	g02725030
   (7h) Retainer Plate

   3. Remove and save retainer plate (7h) .
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   Illustration 30	g02725031
   (7d) Washer Seals (one coalescer element removed for clarity)

   4. Remove and save washer seals (7d) .
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   Illustration 31	g02725038
   (7) Typical Coalescer Vessel (7e) Typical Separator Canister (7f) Typical Coalescer Element

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

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

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

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

3. Install clean water separator canister and new coalescer element.
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   Illustration 32	g02725041
   (7) Typical Coalescer Vessel. (7e) Typical Separator Canister. (7f) Typical Coalescer Element.

   1. Place new coalescer element (7f) inside separator canister (7e) and install in coalescer vessel (7) centered over threaded rod.
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   Illustration 33	g02725045
   (7d) Washer Seals (one coalescer element removed for clarity)

   2. Install washer seal (7d) on each threaded rod.
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   Illustration 34	g02725048
   (7b) Filter Nut (7h) Retainer Plate (7i) Bracket Nut

   3. Install retainer plate (7h), filter nuts (7b), and bracket nuts (7i). Do not over tighten nuts.
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   Illustration 35	g02725049
   Typical Coalescer Vessel Seal (7g) Shown

   4. 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 36	g02725051
   (7) Coalescer Vessel (7a) Coalescer Vessel Cover

   5. Install coalescer vessel cover (7a) on coalescer vessel (7) and secure with hardware removed earlier. Tighten bolts to 68 N·m (50.2 lb ft).

Note: Vessel cover weighs 42.6 kg (93.92 lb). Get help, or use an appropriate lifting device to install the cover.

Clean The Filtration System

1. For ease of operation and maintenance, clean the unit with a nonsolvent 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 very 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 kPa (25.0 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.
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   Illustration 37	g02725053
   (3a) Inlet Ball Valve Handle In CLOSED Position (20a) Outlet Ball Valve Handle In CLOSED Position

   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 38	g02725057
(5) Differential Pressure Gauge

3. Check both differential pressure gauge (5) follower needles for readings above 172 kPa (25.0 psi) to help identify which filter is restricted.

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. Resume refueling operation.

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

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Illustration 39	g02725061
Typical Slug Valve (18) Shown in SET Position

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.

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".

Service Parts

Illustration 40	g02725064
(24) Typical Pre-Filter Element (25) Typical Coalescer Element (26) Typical Separator Canister

Troubleshooting

Maintenance Record

Replace filters at least every six months. Clean debris from vessels annually, or as needed to maintain cleanliness.