370-8569 Bulk Fuel Filtration Group 100 GPM Flow Rate{0599, 0680, 0706, 0782, 1250, 1280} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

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.

General Information

Introduction

Illustration 3	g02730908

The 370-8569 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 757 L/min (100 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 elements 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 elements cleaned whenever differential pressure reaches 103.4 kPa (15.0 PSIG).

The slug valve also limits flow through the system to 757 L/min (100 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 (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 BFFS unit is installed in series between the fuel pump on the fuel storage tanks and the fueling station, or fuel transport vehicle.

Depending on the fuel cleanliness quality, pre-filtration may be required on the fuel entering the fuel storage tank or between the fuel storage tank and the BFFS, 370-8569, or both. Consult your Cat® dealer on this and other fuel management best practices.

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

References

Information Release Memo, PELJ0671, "Bulk Fuel Filtration"

Publication: PEHJ0156, "Bulk Fuel Filtration"

Service Manual, SEBU6250, "Caterpillar Machine Fluid Recommendations"

Specifications

Additional Contact Information

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

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

International: 1-309-578-7372

Nomenclature

Illustration 4	g02732101

Operation Section

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

Installation

1. The shipping weight of the 370-8569 Bulk Fuel Filtration System is 1474 kg (3250 lbs). Uncrate the unit. 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. Use two inner or two outer lift points.

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Illustration 5	g02731784
(23) Mounting Brackets

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

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Illustration 6	g02731794
(13) Water Drain

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

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Illustration 7	g02731829
(6) 150 psi Pressure Relief Valve

4. Use an approved pipe or hose to extend the 150 psi pressure relief valve (6) outlet to an inlet on the fuel reservoir. Or use 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 disposal is important when working with fuels. Follow all Federal, State, and Local regulations on disposal of waste products.

   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 8	g02732177
(2) Bulk Fuel Filtration System Inlet

5. Use approved pipe or fuel hose 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 9	g02732195
(21) Bulk Fuel Filtration System Outlet

6. Use an 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.

   Note: For proper performance, inlet and outlet lines are required to be 50.8 mm (2 inch) or larger. Refer to "Frequently Asked Questions", illustrations 42 and 43.

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 has been opened.

1. OPEN inlet and outlet ball valves.
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   Illustration 10	g02732211
   (3a) Inlet Ball Valve Handle in OPEN Position (20a) Outlet Ball Valve Handle in OPEN Position

   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.

2. Turn ON the fuel supply pump at the fuel supply. Fill bulk fuel filtration system at no more than one third (1/3) the rated flow (33 gpm in this case).

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Illustration 11	g02732219
(4) Pre-filter Vessel (7) Coalescer Vessel (16) Automatic Air Release Valves

3. Manually vent air from both the pre-filter vessel (4) and the coalescer vessel (7), one at a time during the initial fill.

   Note: Both the pre-filter (4) and the coalescer (7) vessels are equipped with automatic air release valves (16). Venting is performed automatically during normal operation. The vented air may contain fuel mist during normal operation and an approved pipe or hose can be connected to the outlet of the air release valves (16) to route it back into the fuel reservoir.

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

4. Once the air is vented out of both pre-filter and coalescer vessels, turn OFF the fuel supply pump.

5. CLOSE inlet and outlet ball valves.
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   Illustration 12	g02732230
   (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 13	g02732250

6. Note the water meter (19) reading and record for future reference.

Operation

1. OPEN inlet and outlet ball valves.
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   Illustration 14	g02732211
   (3a) Inlet Ball Valve Handle in OPEN Position (20a) Outlet Ball Valve Handle in OPEN Position

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

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

3. Dispense fuel from the fueling station.

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Illustration 15	g02732258
(5) Differential Pressure Gauges

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

Note: A differential reading of 103 kPa (15 PSIG) or above can indicate that filter element replacement service is required. Refer to the Maintenance Section in this manual.

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

6. CLOSE inlet and outlet ball valves.
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   Illustration 16	g02732230
   (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.

      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 Service Manual, SEBU6250, Caterpillar Machine Fluids 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 17	g02732230
   (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 away from the outlet pipe, (20a) so that the handle is aligned with the outlet pipe, as shown.

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Illustration 18	g03656290
(4) Pre-filter Vessel (4b) Manual Air Release Vent Valves (7) Coalescer Vessel (16) Automatic Air Release Valves

3. Drain approximately 284 L (75 gal) of fuel from pre-filter and coalescer vessels into an approved tank or container.

   1. To aid fuel drain-down from pre-filter and coalescer vessels, slowly OPEN the air release vent valves (4b) by turning the handle 90°.

   2. After the fuel is drained, securely CLOSE both vent valves by turning the handle 90°.

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 disposal is important when working with fuels. Follow all Federal, State, and Local regulations on the disposal of waste products.

Filter Element Replacement

Replace all filter elements whenever differential pressure reaches 103 kPa (15 PSIG).

Replace Pre-filter Elements

1. Complete steps 1 through 3 in the Shutdown Procedure section of this manual.

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NOTICE
Drain vessel completely to prevent poor filtration and/or damage to components. Remove accumulated contaminates each time a pre-filter element is changed. Completely clean out any debris from inside the vessel.

2. Remove dirty pre-filter element from pre-filter vessel.
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   Illustration 19	g02732279

   1. Remove 8 fasteners (4c) from assembly of vessel and lid (4a). Remove pre-filter vessel lid (4a) .

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

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   Illustration 20	g02732842

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

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

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

      Note: Examine the filter element for debris that could indicate problems such as microbial growth, and discard the contaminated pre-filter element.

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Illustration 21	g02732836
Remove Pre-filter Element

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

3. Install new pre-filter element.
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   Illustration 22	g02732839
   Replace 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 23	g02732842

   2. Install element hold-down plate (4e) and hardware. Tighten the fasteners to 14 Nm (10 lbf.ft).
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   Illustration 24	g02733011

   3. Remove and discard vessel cover 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 cover (4a) making sure that seal is correctly seated. Tighten fasteners (4c) to 81 Nm (60 lbf.ft).

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

Replace Coalescer and Separator Filter Elements

Illustration 25	g02733096

1. Complete steps 1 through 3 in the Shutdown Procedure Section of this manual.

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NOTICE
To prevent poor filtration and/or damage to components, drain vessels completely and remove accumulated contaminates each time an element is replaced. Completely clean out any debris from the inside of all vessels.

2. Remove water separator elements and coalescer elements.

   1. Use wrenches (dealer supplied) to loosen and remove fasteners securing vessel cover (7a). Reposition fasteners to allow removal of coalescer vessel cover from coalescer vessel (7). Save all hardware for reuse. Once all fasteners have been repositioned to allow removal, use the provided hydraulic jack (7j) to lift the coalescer vessel cover (7a). Rotate the cover about the pivot point to allow access to the coalescer element and separator canister.

      Note: Vessel cover weighs 111 kg (245 lb).

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   Illustration 26	g02733270

   2. Use a socket wrench to loosen and remove three coalescer bracket nuts (7i) and two coalescer nuts (7b). Save hardware for reuse.
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   Illustration 27	g02733280

   3. Remove and save retainer plate (7h) .
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   Illustration 28	g03209320

   4. Remove separator bracket nuts (7d), and separator nuts (7c) .

   5. Remove each coalescer element from the vessel and inspect the inside surface of the vessel (7e) for damage.

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

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

      Note: Examine the element for debris that could indicate problems such as microbial growth, and discard the contaminated element.

   6. Clean contaminants and debris from separator element using soft bristle brush and clean fuel. Replace any separator element that is damaged or corroded.

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

3. Install clean separator elements and new coalescer elements.

   Note: All coalescer elements should be replaced at the same time.

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   Illustration 29	g03209396

   1. Place clean separator element and coalescer elements inside coalescer vessel, centered over threaded rods.
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   Illustration 30	g02733436

   2. Install separator nuts (7c), coalescer retainer plate (7h), coalescer nuts (7b), and all associated hardware. Tighten to 14 Nm (10 lbf. ft)
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   Illustration 31	g03209438

   3. Install both the coalescer and separator brackets and associated hardware on each threaded rod.

   4. Install coalescer bracket nuts and separator bracket nuts on each threaded rod. Do not over-tighten nuts.

   5. Remove coalescer vessel seal and replace with new seal included in element replacement kit.

   Note: The coalescer vessel seal or O-ring should be replaced each time it swells from contact with fuel. Make sure that the seal groove is clean and free of debris before installing a new seal.

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   Illustration 32	g02733451

   6. Reposition coalescer vessel cover (7a) over coalescer vessel. Use caution and lower cover using lift jack (7j) to place the cover onto the vessel.

      Note: Vessel cover weighs 111 kg (245 lb). Use caution when rotating cover.

   7. Reposition coalescer vessel cover bolts to secure coalescer vessel cover (7a) to coalescer vessel (7). Tighten all fasteners to 135 -150 Nm (100 - 110 lbf. ft).

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. Near the base of the unit is a water drain plug (12). 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. Proper disposal 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 (8) with a clean, dry cloth to maintain visibility.

Start up After Maintenance

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

For step by step information, refer to Startup Procedure in the Operation Section of this manual.

Slug Valve Reset

Illustration 33	g02733544
(18) Differential Pressure Slug Valve

Differential fluid pressure above 172 kPa (25.0 psi), caused by filter element restrictions, will result in the slug valve (18) 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.

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Illustration 34	g02732230
(3a) Inlet Ball Valve Handle in CLOSED Position (20a) Outlet Ball Valve Handle in CLOSED Position

2. CLOSE inlet and outlet ball valves.

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

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

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Illustration 35	g02732258
(5) Differential Pressure Gauges

3. Check both differential pressure gauge (5) follower needles for readings above 103 kPa (15 psi) to help identify which filters are restricted.

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Illustration 36	g02733544
(18) Differential Pressure Slug Valve

4. Observe water level in sight glass (8). If slug valve float control is above mid-point, wait for excess water to drain through water drain valve (12). Additionally, use manual drain valve (11) to drain water from coalescer vessel.

5. Once water level in sight glass (8) goes below mid-point, reset slug valve (18) by moving lever from TRIPPED position to SET position.

Note: If slug valve will not reset, or 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 Service Manual, SEBU6250, Caterpillar Machine Fluid Recommendations.

Service Parts

Illustration 37	g02733610
(24) Typical Pre-filter Element (25) Typical Coalescer Element (26) Typical Separator Canister

Illustration 38	g03658243

Illustration 39	g03678174

Troubleshooting

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 and gloves 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 and coalescer vessel manual vent valves, to allow trapped air to escape before removing the covers.

• Electrical hazard

If the bulk filtration unit contains an electrical heating element 307-0655 or 307-2569, it must be disconnected prior to any maintenance or service by a certified Electrician. 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 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 pressure is relieved.

4. Both pre-filter and coalescer vessels are drained. Fuel drained from the two vessels SHOULD NEVER be placed back into the filter/ coalescer vessel. Drained fuel should be placed back into the bulk fuel storage tank if it has not been contaminated and should be filtered going in.

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 BFFS?

The BFFS requires no electrical, pneumatic, or hydraulic power for proper operation. Units that work in climates where there is a possibility of freezing water, can be equipped with electrical heating elements. In this case, a continuous electrical power source must be available.

Can the equipment work outdoors? Does It require constant monitoring?

The BFFS has a rugged design and is prepared to perform without any supervision under inclement weather conditions. However, routine monitoring of proper operation is required, such as checking for leaks and monitoring the pressure gauges and water accumulation in the coalescer vessel. Consider placing the BFFS unit in a shed or under a canopy, to allow changing of elements in inclement weather, keeping dust and dirt out of the unit. Allow 48" clearance above BFFS for maintenance access.

Does the BFFS have to be fixed on the floor?

The BFFS has a drip pan welded skid, which is normally bolted 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 BFFS 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 rated at 4-10 µ (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 are preferred. If rubber hose is used, the hose should be a minimum of 1 inch larger in diameter than 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 openings 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 40 psi. This is the pressure where the slug valve starts to operate. The slug valve performs 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.

What is the function of the coalescer element and separator element in the vessel?

The coalescer 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 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 element and be suspended in the fuel. Without the separator element, these small droplets could flow through the unit.

The separator element complements the function of the coalescer element. The separator element prevents the passage of the dislodged small water droplets to the fuel outlet. The separator element consists of a fine Teflon coated wire screen. This screen is hydrophobic and repels the water droplets, preventing any water from leaving the unit with the fuel. 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 BFFS, however some customers prefer these alternate lines in order to not disrupt fueling operations should the BFFS 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 BFFS downtime.

What is the water separation capability of this unit?

The coalescer and separator element will remove free water to less than 0.01% (100 ppm) contained in the outlet fuel. The efficiency of water removal is dependent on the amount of water in the fuel.

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.

The fuel flow rate should be limited to 35 GPM or less during initial fill of BFFS to prevent sudden pressure spikes.

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

There is no recommended distance between the supply pump and the BFFS. Experience shows that installations should provide minimal flow restriction both to and from the BFFS. Steel piping with long radius 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 BFFS.

Illustration 40	g03699772
Iron Long Radius/Sweep Elbow

What would cause the unit relief valve to open?

The purpose of the relief valve is to open if the system is exposed to a higher operating pressure than 150 psi. The relief valve prevents over pressurization of the unit which can happen If the ambient temperature were to increase significantly, or bright sun caused the fuel in the unit to warm and expand significantly.

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 41.

Illustration 41	g03419553
The arrow in Illustration 41 indicates the Slug Valve in the "TRIPPED" position.

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

These three components are integral to the BFFS, 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 the 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 BFFS. This feature prevents contaminated fuel from leaving the BFFS .

Maintenance

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

Pre-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. Pre-filter life will largely depend on two factors:

a) How contaminated is the inlet fuel supply?

b) How much fuel is being used?

Pre-filters are designed to last at least a month between changes in most applications, but would require immediate replacement once a 15 psi differential pressure is reached across the pre-filter vessel. The same rule applies to coalescing filter elements. It is imperative the maintenance record (Table 8) is updated for all element replacements with differential pressure readings noted down for both vessels. In some cases, the coalescer elements last longer, but should be replaced at least once a year.

There are a few conditions, which may result in coalescing filter elements to be changed more often:

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

b) Pre-filter 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 pre-filter and to the coalescing elements.

c) Microbial growth in the bulk storage tank will plug both pre-filter 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. They are reusable and do not need to be replaced unless the screen is physically damaged. Refer to "Separator Cleaning Procedure" (Illustration 44).

What regular maintenance should be performed on the unit?

Large debris and dirt trapped in the pre-filter elements may fall out and over time collect in the bottom of the pre-filter vessel. Both the pre-filter 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 BFFS units. (Refer to Tables 4 and 5.)

How long is the warranty period for this unit?

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

Application and Specifications

Does the BFFS 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.

An example is dish washing soap used with water to remove grease from a cooking pan. The water has high surface tension and does not want to dissolve the grease, which forms into droplets. 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 disarming it and rendering the coalescer completely useless.

Note: Additional fuel treatment may be needed such as clay treaters if bio-fuel content is very high in order to reduce/remove the surfactants.

How do diesel additives affect the operation of the BFFS?

As with bio-fuels, fuel additives can affect the efficiency of the BFFS. Some additives act as mild surfactants, and can reduce coalescer efficiency. Others contain salts, which cannot be captured by the pre-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 40 psi of fuel flow across it.

Note: Contact your Cat® dealer if experiencing issues with the slug valve.

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.

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 differential pressure across inlet and outlet.

The BFFS senses differential pressure across both the pre-filter elements and coalescer elements. If the valve senses a high (25 psi or above) differential pressure across the pre-filter and coalescer together, 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 42	g03658392

Are the connecting flanges standard industrial size?

Yes. The isolation valves at the supply and discharge end of the BFFS 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.

Illustration 43	g03699866
Class 150 Stainless Steel Welding Neck Flange ASTM A182 Flanges, ANSI B16.5

Separator Cleaning Procedure

Illustration 44	g03699877

It is recommended that this procedure is carried out with every coalescer change to ensure full potential and longer life of the separator. Make sure that hands are kept clean and free of grease or other contamination throughout the cleansing operation. It is also recommended that gloves (preferably thin rubber) be worn throughout this operation to avoid contact between bare hands and the separator screen / mesh.

1. CAREFULLY remove each element from the filter separator.

2. Submerge the element in clean, dry fuel and wash it using a gentle, reciprocating action, holding the element first by one end cap and then the other. (DO NOT touch the separator screen/mesh with your bare hands, or allow any grease to come into contact with the element.)

3. Holding the element by the endcaps, visually inspect the entire surface of the screen for damage and contamination. If there are any visible flaws or debris that have not been removed by washing, the cartridge should be replaced.

4. While separator is fuel wet, hold the element horizontal and allow tap water to drip onto the screen. The water must not be sprayed and it must not fall more than 3" (7.5 cm) before contacting the screen. The water will run off instantly if the element is not contaminated. Continue testing the element by slowly rotating and moving it back and forth until the entire surface has been tested. If the water does not run off, but disappears through the screen and is found inside the element, then the element has to be further cleaned as described in step.

5. If the element passes the surface inspection (step 3) and the water test (step 4), rinse it thoroughly in clean fuel to remove traces of water and air dry prior to reinstalling.

6. If the element fails the water test (step 4) or it may be further cleaned by repeating the cleaning stage (step 2) using isopropyl alcohol in place of fuel. After cleaning, the element should be drained and rinsed in clean, dry fuel to remove all traces of isopropyl alcohol if used. Another alternative is to use a spray of hot water (not from a pressure washer). Allow the cartridge to fully dry. After using either procedure, repeat the water test (step 4). If the element does not pass the water test after this operation, it must be replaced.

7. If there are visible tears, nicks, or cuts, they can be repaired as long as they are not larger than 1/8" in diameter. Use brightly colored fingernail polish or epoxy to repair the area. The nail polish allows repairs to be easily observed in the future. After you have repaired the element, wet the element in fuel and repeat the water test (step 4).

Note: The use of detergents (i.e., soap, powder cleanser of any kind), steam, or compressed air during any of the above operations IS NOT RECOMMENDED because they can affect the operation of the separator.

Maintenance Record

Replace filters whenever differential pressure (DP) reaches 15 psi. Clean debris from vessels each time pre-filter or coalescer elements are replaced to maintain cleanliness.