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Introduction
Important Safety Information
European Union Compliant, CE, and WEEE marked
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| Illustration 1 | g02139237 |
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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.
Personal Protection/Important Information
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| Illustration 2 | g02166423 |
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Personal Protection/Important Information | |
Prohibited Action
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No Smoking |
Hazard Avoidance
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Crushing Hazard (foot) |
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Crushing Hazard (hand) |
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Pinch Point |
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Fire Hazard |
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Electrical Shock - Hazard |
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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. |
| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
General Information
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| Illustration 3 | g03731331 |
Introduction
The 464-8510 Fuel Filtration System (PFFS) is a portable unit designed to remove particulates and water from diesel fuel in a single pass. The maximum rated flow for this system is
The system has a high efficiency filter element for excellent particulate removal and utilizes coalescing media for superior water separation properties. Given the compact size, the unit can easily be transported between different job sites and moved to different locations to service all types and sizes of equipment.
Applications
The Cat Bulk Fuel Filtration System is intended for use in any application where users store fuel for machines or engines. The unit is to be used to filter the fuel being dispensed to the machine or equipment.
Consult your Cat dealer on this and other fuel management best practices.
The system is powered by an onboard 12V DC pump.
References
Information Release Memo, PELJ1706, "Portable Bulk Fuel Filtration System"
Publication: PEHJ0156 "Bulk Fuel Filtration"
Service Manual, SEBU6250, "Caterpillar Machine Fluid Recommendations"
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
Nomenclature
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| Illustration 4 | g03731453 |
| 464-8510 Bulk Fuel Filtration System Serviceable Parts | |||
| Item | Qty | Part No. | Description |
| 1 | 1 | 464-8511 | Mounting Bracket |
| 2 | 1 | 464-8512 | Pump (12V) |
| 3 | 1 | 464-8513 | Nozzle |
| 4 | 1 | 461-5138 | Filter Housing Assembly |
| 5 | 1 | 7X-3387 | Sampling Valve |
| 6 | 1 | 6V-0852 | Dust Cap |
| 7 | 1 | 8T-0863 | Pressure Gage |
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| Illustration 5 | g03731385 |
| Replacement Filter Elements | |||
| Item | Part No | Qty | |
| 4a | 461-6622 | 1 | 1 µ m Element |
| 4b | 461-6623 | 1 | 5 µ m Element |
| 4c | 461-6624 | 1 | 25 µ m Element |
Note: The O-ring is provided with replacement elements.
Note: The filtration cart, 464-8510 comes with filter element, 461-6622 installed.
Operation Section
Note: Follow all applicable industry standards and all governmental guidelines when installing, operating, and maintaining the bulk fuel filtration system.
Installation
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| Illustration 6 | g03823274 |
The unit comes with a nozzle and appropriate piping for dispensing the fuel at the cart outlet. The user will need to provide piping to connect the fuel source to the inlet valve. The inlet elbow has a size of 2 inches, National Pipe Thread (NPT). This could be reduced to 1.5 inches if necessary. There are some camlock fittings that can be typically used on hoses for quick connect/disconnect.
| NOTICE |
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DC powered pumps are designed to operate on either 12 VDC or 24 VDC (depending on model). Where applicable, use the supplied battery cable to supply power to the pump from a 12 VDC or 24 VDC battery. A 30 amp fuse (20 amp fuse on 24 VDC motors) should be installed on the battery cable (see wiring diagram page 9) to protect the wire in case of electrical short. |
Note: The fuse has been installed and is located in the junction box on the motor.
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| Illustration 7 | g03823398 |
| NOTICE |
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Voltage drop in wiring varies depending on the distance from the battery to the pump and the gauge of the wire used. If the distance is greater than 20', refer to national, international, or local electrical codes to ensure that the wire is of the correct size for this application. |
Operating Instructions
- Connect the battery cables on the cart to the 12 VDC power supply.
- Remove dispensing nozzle from the nozzle boot.
- Move the switch lever to the "ON" position to power the pump.
- Insert the dispensing nozzle into the container to be filled.
- During the initial use of the unit, insure that the vent valve on the filter housing is open. When fluid starts to appear, the valve should be closed.
- Operate the nozzle to dispense fluid. Release nozzle when the desired amount of fluid has been dispensed.
Show/hide table
Illustration 8 g03842046 - Move the switch lever to the "OFF" position to turn off the pump.
Show/hide table
Illustration 9 g03842043 - Remove the dispensing nozzle from the container being filled and store it in the nozzle.
Padlocking
The pump nozzle can be padlocked to the pump for added security. With the pump turned off, and the nozzle in the stored position, a padlock can be inserted through the locking link and the nozzle handle.
The locking link is on the nozzle side of the pump, and can be pivoted into position to work with various nozzles.
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| Illustration 10 | g03842056 |
Note: It is recommended that the vent and drain valves or plug be opened once each day to permit the escape of entrapped air and accumulated water. This should be accomplished while the unit is in operation to insure sufficient pressure to vent and drain.
Water Sight Glass
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| Illustration 11 | g03842381 |
The water sight glass provides an easy means to detect water in the stream. The weighted ball, visible in the sight glass, will float only when water is present. The floating ball is an indication water should be drained from the housing to prevent both cartridge contamination and water downstream of the housing.
Maintenance Section
The filter/coalescer element should be replaced when (1) effluent flow is noticeably reduced, (2) differential pressure across the unit reaches 15 psid (the pressure indicator will be in the red), or (3) when the filter has been in use for the recommended time period. For this unit, it is recommended to replace the filter cartridge once yearly.
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| Illustration 12 | g03842463 |
The pump suction is provided with a screen to protect the pump from internal damage caused by debris. The screen may become clogged with debris causing a low flow condition. If this is suspected, remove the pump adapter to access the screen. Clean the screen and reinstall. This should be the first step in troubleshooting flow reduction.
If any of the above noted that conditions indicate that the filter element replacement is necessary, follow procedures below:
- Disconnect power to the unit.
- Open the vent valve on the cover of the housing. Allow the unit to thoroughly vent before opening the cover.
- Open the drain plug or drain valve on the housing bottom. Allow all fluid to drain from the unit.
- Loosen swing bolts, then remove the housing body and element.
Show/hide table
NOTICE Due to the toxic effects of some additives used in filtered fluids, care should be exercised in handling the expended cartridge and all internal parts that have been in contact with the filtered products.
- Remove and discard the expended cartridge and closure o-ring in a FIRE-SAFE place.
- Flush the interior of the housing with clean, processed, filtered product, or a suitable solvent. A nonmetallic bristle brush will help to remove caked on debris. Rinse the housing and unit cover with clean solvent and dry with soft, lint-free wiping cloth
- Remove a new filter element from the shipping carton. Closely inspect the element before installing. Slide the new element into the housing.
- Install new closure o-ring. Reassemble the body and align swing bolts with cover bolt slots. Tighten the bolts attaching the body to the housing cover. Torque to 10ft/ lbs (~13.6 Nm).
- Close the drain plug or valve on the bottom of the housing.
- Reconnect the cart to the power source. Slowly open the inlet valve and allow the unit to fill completely. Operate the outlet nozzle as before.
- Leave the vent valve on top of the unit open, to allow entrapped air to escape while filling
- When a small amount of fluid flows from the vent , close the vent tightly
- During initial filling, after above maintenance, and while unit is in operation, examine housing and all connections for leaks.
- Repair any leaks and replace damaged or deteriorated parts such as closure o-ring, vent and drain valves, or plug as necessary.
Filter Element Replacement
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| Illustration 13 | g03731760 |
The top flat gasket is only used as a spacer to ensure a positive seal at the bottom o-ring. When assembly difficulty is encountered, this top flat gasket can be removed while still maintaining a positive seal at the bottom o-ring.
| NOTICE |
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Full flow monitors (water absorbing elements) are not for use with fuel containing anti-icing additive (FSII Prist, Diegme). This includes premixed and military fuels containing this additive. use only non-sparking tools when performing any maintenance or service work on this equipment. |
Service Repair Parts
| 464-8510 Bulk Fuel Filtration System Serviceable Parts | |||
| Item | Qty | Part No. | Description |
| 1 | 1 | 464-8511 | Mounting Bracket |
| 2 | 1 | 464-8512 | Pump (12V) |
| 3 | 1 | 464-8513 | Nozzle |
| 4 | 1 | 461-5138 | Filter Housing Assembly |
| 5 | 1 | 7X-3387 | Sampling Valve |
| 6 | 1 | 6V-0852 | Dust Cap |
| 7 | 1 | 8T-0863 | Pressure Gage |
Troubleshooting
The following Troubleshooting guide is provided to offer basic diagnostic assistance in the event that you encounter abnormal service from your Portable Fuel Filtration system.
| Troubleshooting Chart | ||
| Symptom | Cause | Cure |
| Pump will not prime | Suction line problem | Check for leaks or obstructions in suction line |
| Bypass valve open | Remove and inspect valve; must move freely and be free of debris. | |
| Vanes sticking | Check vanes and slots for nicks, burrs, and wear.* | |
| Excessive rotor or vane wear | Inspect rotor and vans for excessive wear or damage. Replace if necessary.* | |
| Vapor lock | Reduce vertical and horizontal distance from pump to liquid. Remove automatic nozzle. | |
| Low capacity | Excessive dirt in screen | Remove and clean screen. |
| Suction line problem | Check suction line for leaks or restrictions. It may be too small, too long or not airtight. | |
| Bypass valve sticking | Remove and inspect valve. Valve must move freely and be free of debris. | |
| Outlet blocked | Check pump outlet, hose, nozzle, and filter for blockage. | |
| Vanes sticking | Check vanes and slots for wear.* | |
| Excessive rotor or vane wear | Inspect rotor and vanes for excessive wear or damage. Replace if necessary.* | |
| Hose or nozzle damage | Replace hose or nozzle. | |
| Plugged filter | Replace filter. | |
| Low fluid level | Fill tank. | |
| Pump runs slowly | Incorrect voltage | Check incoming line voltage while pump is running. |
| Vanes sticking | Inspect vanes and slots for nicks, burrs, and wear.* | |
| Wiring problem | Check for loose connections. | |
| Motor problem | Return to place of purchase. | |
| Motor stalls/ fuse blows or thermal protector trips repeatedly | Bypass valve sticking | Remove and inspect valve. Valve must be free of debris. |
| Low voltage | Check incoming line voltage while pump is running. | |
| Excessive rotor or vane wear | Check rotor and vanes for excessive wear and damage.* | |
| Debris in pump cavity | Clean debris from pump cavity. | |
| Motor overheats | Pumping high viscosity fluids | These fluids can only be pumped for short periods of time. (Less than 30 minutes duty cycle) |
| Clogged screen | Remove and clean screen. | |
| Restricted suction pipe | Remove and clean pipe. | |
| Motor failure | Return to place of purchase. | |
| Pump rotor lock-up | Clean and check pump rotor and vanes. | |
| Motor inoperative | No power | Check incoming power |
| Switch failure | Replace switch (KIT120SW) | |
| Motor failure | Return to place of purchase. | |
| Thermal protector failure | Return to place of purchase. | |
| Incorrect loose wiring | Check wiring. | |
| Fluid leakage | Bad O-Ring gasket | Check all O-Ring gaskets. |
| Dirty shaft seal | Clean seal and seal cavity. | |
| Bad shaft seal | Replace seal | |
| Incompatible fluid | Refer wetted parts list to fluid manufacturer. | |
| Loose fasteners | Tighten fasteners. | |
| Pump hums but will not operate | Motor failure | Return to place of purchase. |
| Broken rotor key. | Remove all debris and replace key. | |
| No fuel flow. | Inlet or outlet valve is closed. | Completely open inlet/outlet valve. |
| Fuel hose is kinked. | Straighten hose and/or provide larger hose. | |
| Differential pressure gage reading greater than 15.0 psi (103.4 kPa) | Replace filter element and clean vessel. | |
| Differential gage reading suddenly drops. | Damaged or ruptured filter element. | Check filter element, and change as needed. |
Note: All repairs marked with an asterisk (*) may require a new Pump (Part No. 464-8512).
| NOTICE |
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Disconnect electrical power and relieve any pressure in the lines prior to servicing this pump. Failure could result in damage to the equipment or injury to the operator. |
Declaration of Conformity
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| Illustration 14 | g06244491 |