370-8571 Bulk Fuel Filtration Group 300 GPM Flow Rate{0599, 0680, 0706, 0782, 1250, 1280} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

European Union Compliant, CE marked

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

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

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

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

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

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

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

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

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

Literature Information

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

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

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

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

Safety Section

The Safety Section lists basic safety precautions.

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

General Information Section

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

Operation Section

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

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

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

Maintenance Section

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

Service Parts Section

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

Safety Icon Nomenclature

Personal Protection/Important Information

Illustration 2	g02166423
Personal Protection/Important Information

Prohibited Action

No Smoking

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

Fire Hazard

Electrical Shock - Hazard

Safety Section

Show/hide table

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.

Show/hide table

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	g03315599

The 370-8571 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 (300 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 every six months, or whenever differential pressure reaches 103.4 kPa (15.0 PSIG).

The slug valve also limits flow through the system to 757 L/min (300 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).

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

Email: dealerservicetool_hotline@cat.com

Applications

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

Note: The system does not require electrical power unless electrical power 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.

References

Service Manual, PEHJ0156, "CAT Bulk Fuel Filtration Systems"

Service Manual, PEHJ0671, "Bulk Fuel Filtration"

Service Manual, SEBU6250, "Caterpillar Machine Fluid Recommendations"

Specifications

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 370-8571 Bulk Fuel Filtration System is 1636.4 kg (3600 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.

Show/hide table



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.

Show/hide table



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.

Show/hide table



Illustration 7	g02731829
(6) 150 psi Pressure Relief Valve

4. Use an approved high-pressure pipe 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.

Show/hide table



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.

Show/hide table



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.

Start-Up Procedure

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

1. OPEN inlet and outlet ball valves.
   Show/hide table
   
   

   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.

Show/hide table



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.

   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.
   Show/hide table
   
   

   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.

Show/hide table



Illustration 13	g02732250

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

Operation

1. OPEN inlet and outlet ball valves.
   Show/hide table
   
   

   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.

Show/hide table



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.
   Show/hide table
   
   

   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.
   Show/hide table
   
   

   Illustration 17	g02732266
   (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 handle is aligned with the outlet pipe, as shown.

Show/hide table



Illustration 18	g02732219
(4) Pre-filter Vessel ( Qty 2) (7) Coalescer Vessel (16) Automatic Air Release Valves

3. Drain approximately 473L (170 gal) of fuel from pre-filter and coalescer vessels by dispensing fuel into an approved tank or container.

   1. To aid fuel drain-down from pre-filter and coalescer vessel, slowly OPEN pre-filter vessel vent valves by turning the valve handle 90°.

   2. After the fuel is drained, securely CLOSE both vent valves by turning the valve 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 every 6 months or whenever differential pressure reaches 103 kPa (15 PSIG), whichever comes first.

Replace Pre-filter Elements

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

Show/hide table

NOTICE
Drain vessel completely to prevent poor filtration and/or damage to components. Remove accumulated contaminates annually, or as needed. Completely clean out any debris from inside the vessels.

2. Remove dirty pre-filter elements from pre-filter vessels.
   Show/hide table
   
   

   Illustration 19	g02741778

   1. Remove 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).

   Show/hide table
   
   

   Illustration 20	g02741787

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

   3. Remove 2 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.

   Show/hide table
   
   

   Illustration 21	g02741794

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

      Note: All fluid and materials used with or on the bulk fuel filtration system must be handled and disposed of properly. Proper disposal 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.

   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.
   Show/hide table
   
   

   Illustration 22	g02741797

   2. Install element hold-down plate (4e) and hardware.
   Show/hide table
   
   

   Illustration 23	g02741857

   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 the seal is correctly seated. Tighten fasteners (4c) to 81 Nm (60 lb ft/lbs).

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

Replace Coalescer and Separator Filter Elements

Illustration 24	g02733096

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

Show/hide table

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

2. Remove water separator canisters and coalescer elements.

   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). Get help, or use an appropriate lifting device to remove cover.

   Show/hide table
   
   

   Illustration 25	g03062577

   2. Use a socket wrench to loosen and remove 6 coalescer bracket nuts (7i) and 5 coalescer nuts (7b). Save hardware for reuse.
   Show/hide table
   
   

   Illustration 26	g03062620

   3. Remove and save retainer plate (7h) .
   Show/hide table
   
   

   Illustration 27	g03062657

   4. Remove 5 separator bracket nuts (7d), and 4 separator nuts (7c) .

   5. Remove each element from the vessel and inspect the separator canister (7e) for damage.

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

   6. Clean contaminants and debris from separator canister. Replace any separator canisters that are damaged or corroded.

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

3. Install clean separator canisters and new coalescer elements.
   Show/hide table
   
   

   Illustration 28	g03062816

   1. Install clean separator canisters and coalescer elements inside coalescer vessel, centered over threaded rods.

   2. Install separator nuts (7c), coalescer retainer plate (7h), coalescer nuts (7b), and all associated hardware.
   Show/hide table
   
   

   Illustration 29	g03062657

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

   Show/hide table
   
   

   Illustration 30	g02733451

   6. Reposition coalescer vessel cover (7a) over coalescer vessel. Use caution and lower cover lift jack (7j) to place the coalescer vessel cover onto the coalescer 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. Tighten all fasteners to 135 -150 Nm (100 - 110 ft/lbs).

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. The base features a base drain plug. 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 fuel. 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 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 31	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.

Show/hide table



Illustration 32	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.

Show/hide table



Illustration 33	g02732258
(5) Differential Pressure Gauges

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

Show/hide table



Illustration 34	g02733544
(18) Differential Pressure Slug Valve

4. Once all restrictions are corrected, 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 35	g02733610
(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.