295-0048 Bulk Fuel Filtration Group 300 GPM Flow Rate{0374, 0599, 0680, 0706, 1250, 1261, 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

Introduction

The 295-0048 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 1136 L/min (300.1 US gpm).

Illustration 3	g02727457

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 butterfly valves are included. 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 kPa (25.0 psi), the slug control valve will close, stopping fuel flow.

Filters should be replaced and separator canisters cleaned every 6 months, or whenever differential pressure reaches 138 kPa (20.0 psi).

The slug valve also limits flow through the system to 1136 L/min (300.1 US gpm) maximum.

The system is equipped with a pressure relief valve located on the coalescer vessel cover. The pressure relief valve prevents the system from being pressurized above 1034 kPa (150.0 psi).

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

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 fuel station, or fuel transport vehicle.

Note: The system does not require electrical power unless it is used in cold climates. Optional 307-0655 Electric Heater (120 V) or 307-2569 Electric Heater (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

Nomenclature

Illustration 4	g02727459

Operation Section

Note: Important: 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 295-0048 Bulk Fuel Filtration System is 1170 kg (2579.4 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 storage tank and 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	g02727462
(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	g02727465
(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	g02727466
(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. This is important when working with fuels. Follow all Federal, State, and Local regulations on disposal of waste products.

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Illustration 8	g02727469
(4) Pre-filter Vessel (4a) Pre-filter Vessel Lid (7) Coalescer Vessel (7a) Coalescer Vessel Cover (15) Davit Arms

5. Use attached davit arms (15) to remove pre-filter vessel cover (4a) and coalescer 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	g02727472
(4) Pre-filter Vessel (4a) Pre-filter Vessel Cover (7) Coalescer Vessel (7a) Coalescer Vessel Cover (15) Davit Arms

6. Use attached davit arms (15) to install filter vessel covers (4a), (7a) onto pre-filter vessel (4) and coalescer vessel (7). Install hardware and tighten to 68 N·m (50.0 lb ft).

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

Note: This unit is equipped with butterfly type inlet and outlet valves. A minimum 10.2 cm (4.0 in) inside diameter pipe or hose connection is required to avoid interference with the valve as it operates.

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Illustration 10	g02727475
(2) Bulk Fuel Filtration System Inlet

7. Use approved pipe or fuel hose (dealer supplied) to connect the 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	g02727477
(21) Bulk Fuel Filtration System Outlet

8. Use approved pipe or fuel hose (dealer supplied) to connect the 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.

1. OPEN inlet and outlet butterfly valves.
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   Illustration 12	g02727480
   (3a) Inlet Butterfly Valve Handle In OPEN Position (20a) Outlet Butterfly Valve Handle in OPEN Position

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

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

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Illustration 13	g02727481
(4) Pre-filter Vessel (7) Coalescer Vessel (16) Automatic Air Release Valves

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

   Note: Both pre-filter (4) and coalescer vessels (7) are 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. This is important when working with fuels. Follow all Federal, State, and Local regulations on disposal of waste products.

3. Once all air is vented out of the pre-filter vessel and coalescer vessel, turn OFF the fuel delivery pump.

4. CLOSE inlet and outlet butterfly valves.
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   Illustration 14	g02727483
   (3a) Inlet Butterfly Valve Handle In CLOSED Position (20a) Outlet Butterfly Valve Handle In CLOSED Position

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

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

Operation

1. OPEN inlet and outlet butterfly valves.
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   Illustration 15	g02727484
   (3a) Inlet Butterfly Valve Handle In OPEN Position (20a) Outlet Butterfly Valve Handle in OPEN Position

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

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

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

3. Dispense fuel from fueling station.

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Illustration 16	g02727488
(5) Differential Pressure Gauges

4. Check differential pressure gauges (5) to monitor the pressure restriction of each filter vessel. A differential reading of 138 kPa (20.0 psi) indicates filter element service is required.

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 delivery pump.

6. CLOSE inlet and outlet butterfly valves.
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   Illustration 17	g02727491
   (3a) Inlet Butterfly Valve Handle In CLOSED Position (20a) Outlet Butterfly Valve Handle In CLOSED Position

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

   2. Fully CLOSE outlet 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 placing filter elements, disconnecting inlet and/or outlet lines, or making any repairs to the system.

1. Turn OFF fuel delivery pump.

2. Position inlet and outlet butterfly valves.
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   Illustration 18	g02727494
   (3a) Inlet Butterfly Valve Handle In CLOSED Position (20a) Outlet Butterfly Valve Handle In OPEN Position

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

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

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Illustration 19	g02727495
(4) Pre-filter Vessel (7) Coalescer Vessel (16) Automatic Vent Valves

3. Drain fuel from pre-filter and coalescer vessels by dispensing approximately 367 L (97.0 US gal) of fuel into an approved tank or container.

   Note: Pre-filter vessel (4) and coalescer vessel (7) are equipped with automatic vent valves (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/or hose connections.

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.

Filter Element Replacement

Replace all filter elements every 6 months, or whenever differential pressure reaches 138 kPa (20.0 psi), whichever comes first.

Replace Pre-filter Element

1. Complete Step 1 through Step 3 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 and accumulated contaminates removed annually, or as needed. Completely clean out any debris from inside the vessels.

2. Remove dirty pre-filter element.
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   Illustration 20	g02727496
   (4) Pre-filter Vessel (4a) Pre-filter Vessel Cover

   1. Use wrenches (dealer supplied) to loosen and remove fasteners securing vessel cover (4a). Save all hardware for reuse.
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   Illustration 21	g02727498
   (15a) Davit Arm Bolt (15) Davit Arm

   2. Use a wrench (dealer supplied) to turn davit arm lift bolt (15a) clockwise (CW) to slightly raise cover. Rotate cover on davit arm (15) pivot enough to gain access to Pre-filter elements.

      Note: Vessel cover weighs 42.6 kg (93.92 lb). Use caution when removing cover.

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   Illustration 22	g02727504
   (4e) Element Hold-down Wing Nut

   3. Remove and save large pre-filter element hold-down wing nut (4e) .
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   Illustration 23	g02727508
   (4f) Typical Pre-filter Element

   4. 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.

   5. Clean contaminants and debris from inside 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. This is important when working with fuels. Follow all Federal, State, and Local regulations on disposal of waste products.

3. Install new pre-filter element.
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   Illustration 24	g02727510
   (4f) Typical Pre-filter Element

   1. Install new pre-filter element (4f) by lowering straight down into pre-filter vessel (4). Make sure each pre-filter element is centered over a standpipe.
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   Illustration 25	g02727514
   (4e) Element Hold-down Wing Nut

   2. Install large pre-filter element hold-down wing nut (4e), hand tight.

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

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

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   Illustration 26	g02727519
   (15a) Davit Arm Lift Bolt (15) Davit Arm

   4. Use davit arm (15) to rotate vessel cover over pre-filter vessel and use wrench (dealer supplied) to turn davit arm lift bolt (15a) counterclockwise (CCW) to completely lower cover.

      Note: Vessel cover weighs 42.6 kg (93.92 lb). Use caution when installing cover.

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Illustration 27	g02727521
(4) Pre-filter Vessel (4a) Pre-filter Vessel Cover

4. Secure cover (4a) to vessel (4) with hardware removed earlier. Tighten all bolts to 68 N·m (50.2 lb ft).

Replace Coalescer and Separator Filter Element

1. Complete Step 1 through Step 3 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 and accumulated contaminates removed annually, or as needed. Completely clean out any debris from inside all vessels.

2. Remove water separator canisters and coalescer elements.
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   Illustration 28	g02727537
   (7) Coalescer Vessel (7a) Coalescer Vessel Cover

   1. Use wrenches (dealer supplied) to loosen and remove fasteners securing vessel cover (7a). Save all hardware for reuse.
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   Illustration 29	g02727539
   (15) Davit Arm (15a) Davit Arm Lift Bolt

   2. Use a wrench (dealer supplied) to rotate davit arm lift bolt (15a) clockwise (CW) to slightly raise cover. Rotate cover on davit arm (15) to gain access to coalescer filters.

   Note: Vessel cover weighs 42.6 kg (93.92 lb). Use caution when removing cover.

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   Illustration 30	g02727540
   (7b) Typical Filter Nut (7i) Typical Bracket Nut

   3. Use a wrench (dealer supplied) to loosen and remove filter nuts (7b) and bracket nuts (7i). Save all nuts for reuse.

      Note: Typical water separator canisters shown. Large units use more and larger canisters and filter elements.

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   Illustration 31	g02727546
   (7h) Typical Retainer Plate

   4. Remove and save retainer plate (7h) .
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   Illustration 32	g02727547
   (7d) Typical Washer Seals (large units have up to eight coalescer canisters with washer seals)

   5. Remove and save washer seals (7d) from coalescer canisters.
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   Illustration 33	g02727549
   (7) Typical Coalescer Vessel (7e) Typical Separator Canister (7f) Typical Coalescer Element

   6. Coalescer elements (7f) are located inside separator canisters (7e). Remove each assembly from vessel and separate the components.

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

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

   8. 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 elements.

   1. Install new coalescer elements (7f) inside coalescer vessel (7), centered over threaded rods.
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   Illustration 34	g02727551
   (7d) Typical Washer Seal (large units have up to eight coalescer elements with washer seals)

   2. Install water separator canisters (7e) over coalescer filter elements (7f) and install a washer seal (7d) on each threaded rod.

      Note: Typical water separator canisters are shown. Large units use larger canisters and filter elements, and large units use a greater amount of canisters and filter elements.

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   Illustration 35	g02727553
   (7b) Typical Filter Nuts (7h) Typical Retainer Plate (7i) Typical Bracket Nu

   3. Install retainer plate (7h), filter nuts (7b), and bracket nuts (7a). Do not over tighten nuts.
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   Illustration 36	g02727555
   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 37	g02727557
   (7) Coalescer Vessel (7a) Vessel Cover (15) Davit Arm (15a) Davit Arm Lift Bolt

   5. Use davit arm (15) to rotate vessel cover (7a) over coalescer vessel (7) and use wrench (dealer supplied) to rotate davit arm lift bolt (15a) counterclockwise (CCW) to completely lower cover.

      Note: Vessel cover weighs 42.6 kg (93.92 lb). Use caution when installing cover.

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   Illustration 38	g02727562
   (7) Coalescer Vessel (7a) Coalescer Vessel Cover

   6. Secure cover (7a) to vessel (7) with hardware removed earlier. Tighten all bolts to 68 N·m (50.2 lb ft).

Clean The Filtration System

1. For ease of operation and maintenance, clean the exterior of the unit with a nonsolvent based cleaner, after each 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 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 delivery pump.

2. CLOSE inlet and outlet butterfly valves.
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   Illustration 39	g02727563
   (3a) Inlet Butterfly Valve Handle In CLOSED Position (20a) Outlet Butterfly Valve Handle In CLOSED Position

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

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

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Illustration 40	g02727567
(5) Differential Pressure Gauges

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

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

Illustration 41	g02727570
Typical Slug Valve (18) Shown in 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 42	g02727573
Typical Filter Elements

Troubleshooting

Maintenance Record

Replace filters at least every 6 months. Clean debris from vessels annually, or as needed to maintain cleanliness.