Tool Operating Manual Tool Operating Manual: 295-5490 Portable Diesel Fuel System Filtration Unit
Tool Operating Manual Tool Operating Manual: 295-5490 Portable Diesel Fuel System Filtration Unit
Tool Operating Manual Tool Operating Manual: 295-5490 Portable Diesel Fuel System Filtration Unit
NEHS0989
July 2006
TOOL
OPERATING
MANUAL
295-5490 Portable Diesel Fuel System
Filtration Unit
SMCS: 0684
Important Safety Information The message that appears under the warning
explains the hazard and can be either written
or pictorially presented.
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
specifically recommended by Caterpillar is
Think Safety used, you must satisfy yourself that it is
safe for you and for others. You should
also ensure that the product will not be
Most accidents that involve product operation, damaged or be made unsafe by the
maintenance, and repair are caused by failure operation, lubrication, maintenance or
to observe basic safety rules or precautions. repair procedures that you choose.
An accident can often be avoided by The information, specifications, and illustrations
recognizing potentially hazardous situations in this publication are on the basis of
before an accident occurs. A person must be information that was available at the time that
alert to potential hazards. This person should the publication was written. The specifications,
also have the necessary training, skills, and torques, pressures, measurements,
tools to perform these functions properly. adjustments, illustrations, and other items can
Improper operation, lubrication, change at any time. These changes can affect
maintenance, or repair of this product can the service that is given to the product. Obtain
be dangerous and could result in injury or the complete and most current information
death. before you start any job.
Do not operate or perform any lubrication,
maintenance, or repair on this product until
you have read and understood the WARNING
operation, lubrication, maintenance, and
repair information. When replacement parts are required for this
product, Caterpillar recommends using
Safety precautions and warnings are provided Caterpillar replacement parts or parts with
in this manual and on the product. If these equivalent specifications including, but not
hazard warnings are not heeded, bodily injury limited to, physical dimensions, type,
or death could occur to you or to other strength, and material.
persons.
The hazards are identified by the “Safety Alert Failure to heed this warning can lead to
Symbol” and followed by a “Signal Word” such premature failures, product damage,
as “DANGER”, “WARNING”, or “CAUTION”. personal injury, or death.
The Safety Alert “WARNING” label is shown
below.
WARNING
The meaning of this safety alert symbol is as
follows:
Attention! Become Alert! Your Safety is
Involved.
2
Contents Literature Information
Literature Information This manual should be stored with the tool
Safety Section . . . . . . . . . . . . . . . . . . . . . . . 3 group.
General Information Section . . . . . . . . . . . . 3 This manual contains safety information,
Operation Section . . . . . . . . . . . . . . . . . . . . 3 operation instructions, and maintenance
information.
Maintenance Section . . . . . . . . . . . . . . . . . . 3
Safety Section Some photographs or illustrations in this
publication show details that can be different
Safety Icon Nomenclature . . . . . . . . . . . . . . 4
from your service tool. Guards and covers
Personal Protection/Important Information 4 might have been removed for illustrative
Prohibited Action . . . . . . . . . . . . . . . . . . . . 4 purposes.
Hazard Avoidance . . . . . . . . . . . . . . . . . . . 4 Continuing improvement and advancement of
Safety Warnings Section. . . . . . . . . . . . . . . 4 product design might have caused changes to
Personal Protection/Important Information . 4 your service tool, which are not included in this
publication.
Hazard Avoidance . . . . . . . . . . . . . . . . . . . . 5
Machine Operation Hazards . . . . . . . . . . . . 5 Whenever a question arises regarding your
service tool or this publication, please consult
Fluid Penetration . . . . . . . . . . . . . . . . . . . . . 6
Dealer Service Tools (DST) for the latest
Parts Replacement . . . . . . . . . . . . . . . . . . . 6 available information.
Intended Usage . . . . . . . . . . . . . . . . . . . . . . 6
Warning Films . . . . . . . . . . . . . . . . . . . . . . . 6 Safety Section
General Information Section The Safety section lists basic safety
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 7 precautions.
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Read and understand the basic precautions
Additional Contact Information . . . . . . . . . . 7 listed in the Safety section before operating or
performing maintenance and repair on this
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . 8 service tool.
Specifications. . . . . . . . . . . . . . . . . . . . . . . . 8
Operation Section General Information Section
Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 The General Information section describes
Connect Grounding Strap . . . . . . . . . . . . . 10 tooling functions and features. It provides
Fill Reservoir Tank . . . . . . . . . . . . . . . . . . . 11 useful information on individual parts,
Kidney Loop Reservoir Tank . . . . . . . . . . . 13 additional tooling, and resources.
Kidney Loop Fuel System . . . . . . . . . . . . . 14 Operation Section
Empty Reservoir Tank . . . . . . . . . . . . . . . . 17
The Operation section is a reference for the
Maintenance Section new operator and a refresher for the
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 19 experienced operator.
Filter Elements . . . . . . . . . . . . . . . . . . . . . . 20 Photographs and illustrations guide the
Cleaning and Storage . . . . . . . . . . . . . . . . 22 operator through correct procedures for using
Service Parts . . . . . . . . . . . . . . . . . . . . . . . 23 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 its capabilities.
Maintenance Section
The Maintenance section is a guide to
equipment care.
3
Safety Section Safety Warnings
Safety Icon Nomenclature Personal Protection/Important
Personal Protection/Important Information
Information
WARNING
Read the manual
To avoid personal injury or death,
MS
M DS
MS
SDS
SD
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carefully read and understand all
M
Material safety data sheet instructions before attempting to
operate any equipment or tools.
Eye protection Do not operate or work on a machine unless
you read and understand the instructions
and warnings in this and all other applicable
Eye protection and ear protection manuals. Contact Dealer Service Tools
(DST) for replacement manuals. Proper care
Face protection is your responsibility. Always follow all State
and Federal health and safety laws and/or
local regulations.
Hand protection
To prevent possible damage to
Inspect equipment your hearing, always wear ear
protection when using this tool
and/or working around noise
Prohibited Action generating tools.
No open flame To avoid eye injury,
always wear protective
glasses or face shield.
No smoking
Make sure no one can
be injured by flying objects or debris when
Hazard Avoidance using tools or working on a component.
Fire hazard Personal injury can result
from slips or falls. DO
NOT leave tools or
Hot surface components laying
around the work area, and clean up all
Pressurized air spilled fluids immediately.
Personal injuries
Pressurized fluid can occur as a
result of using
Fluid spray hazard pressurized air.
Maximum air pressure at the nozzle must be
below 205 kPa (30 psi) for cleaning
Fluid vapor hazard purposes. Wear protective clothing,
protective glasses, and a protective face
High-pressure fluid hazard shield when using pressure air.
Slipping hazard
Tripping hazard
4
Hazard Avoidance Machine Operation Hazards
WARNING WARNING
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Always consult the Material Safety Only adequately trained and
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SSS
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DDDData Sheet for chemical hazards instructed personnel should be
and first aid instructions for the authorized to operate the portable
fluids being used. These sheets diesel fuel system filtration unit.
should be available from the manufacturer /
supplier of the fluid(s).
Operators should be aware that
Clean up all leaked or dangers exist when using the portable
spilled fluids immediately. diesel fuel system filtration unit and
Diesel fuel leaked or related attachments. Improper
spilled onto any hot procedures create risk for the operator and
surfaces or electrical components can cause bystanders. DO NOT operate the filtration unit
a fire, resulting in personal injury or death. until checking to make sure no one will be
endangered.
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Always follow Inspect all component parts of this
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SSS
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DDD c h e m i c a l tool before each daily use. Check
manufacturers for damage or excess wear on any
instructions for part. Replace all damaged or worn
proper handling of diesel fuel. Diesel fuel parts immediately. Never operate equipment
exposed to open flame or sparks can cause with a known malfunction or leak.
a fire, resulting in personal injury or death.
The portable diesel fuel
High pressure in excess of system filtration unit is
137,900 kPa (20,000 psi) capable of producing
can be trapped in the static electricity. The
engine fuel injection filtration unit must always be grounded to
system and related components. To avoid the machine, with the supplied ground strap,
personal injury or death, always follow prior to making any fuel system
specific engine guidelines to purge the fuel connections. Static electricity (sparks) can
system of any pressure. cause a fire, resulting in serious injury or
death.
Pressure up to 345 kPa
(50.0 psi) can be trapped
in the filtration unit and
related components. Use
caution when disconnecting hoses or
fittings. Pressure that is released can cause
fuel spray.
To avoid contact
with diesel fuel,
always wear
protective
glasses or face shield and protective
clothing, when servicing filters or other
components.
5
Fluid Penetration Warning Films
Make sure the warning film is on the filtration
WARNING unit and legible at all times. For replacement
films, contact Dealer Service Tools.
Leaking fluid that is under
pressure can penetrate
body tissue. Fluid
penetration can cause
serious injury and possible death. A pin hole
leak can cause severe injury. If fluid is injected
into your skin, you must obtain treatment
immediately. Seek treatment from a doctor
that is familiar with this type of injury.
Parts Replacement
WARNING Warning Film Located On Diaphragm Pump.
6
General Information Section Initially, an automatic particle counter should
be used to verify the cleanliness of the diesel
Introduction fuel in the reservoir tank and/or the engine fuel
system. After the initial verification, periodic
The 295-5490 Portable Diesel Fuel System audits should be performed to assure
Filtration Unit cleans diesel fuel systems by continued performance to meet cleanliness
removing contaminants in the fuel. This fuel specifications.
system filtration unit combines an air powered
diaphragm pump with a five micron filter
element in a compact, lightweight portable
package. Features
• Air powered diaphragm pump for
dependable pumping action.
• Dirty filter indicator shows when filter
elements require service.
• 18.9 L (5 gal) tank capacity.
• Lightweight, portable design for easy
transport to the work site.
• Includes basic suction/return hose and
discharge/pressure hose assemblies.
Additional dealer-supplied adapters are
required.
295-5490 Diesel Fuel System Filtration Unit.
The portable diesel fuel system filtration unit Additional Contact Information
should be used to clean the diesel fuel system For additional product support questions
before engine re-start, or after replacement of concerning this tool, contact the Caterpillar
a failed fuel system component. It can also be Dealer Service Tools Hotline at:
used to ensure the cleanliness of a fuel system
when the condition of the fuel in the system, or U.S.A.: 1-800-542-8665
specific components, is not known. Illinois: 1-800-541-8665
The filtration unit can clean the diesel fuel Canada: 1-800-523-8665
within the reservoir tank, and then, once World: 1-309-675-6277
connected to the engine fuel system, kidney Fax: 1-309-494-1355
loop fuel through the filter element, reservoir [email protected]
tank, and engine fuel system until the desired
level of cleanliness is achieved.
7
Nomenclature NOTE: Included hoses have quick disconnect
fittings on the end. ON/OFF valve and all
other adapters required for connection to
specific fuel systems must be dealer supplied.
Specifications
295-5490 Diesel Fuel System Filtration Unit
Air Diaphragm Pump 138 to 276 kPa
(Operating Pressure Range) (20.0 to 40 psi)
Pressure Air Relief Valve 345 kPa (50.0 psi)
Maximum Output Pressure Pressure of the fluid
pumped should be
(1) Reservoir Tank. (2) Filler Cap. equal to the air inlet
(3) Discharge/Pressure Hose. pressure.
(4) Suction/Return Hose. (5) Ground Strap. Tank Capacity 18.9 L (5.0 gal)
Fluid Cycle 0.57 Lpm (.15 gpm)
Standard Filter Five micron
S·O·S Valve Standard
Operating Temperature 4.4 to 65.5°C
(40 to 150°F)
Noise Level 78 dB at 483 kPa
(70 psi) air pressure
Overall Dimensions (w x d x h) 365 mm (14.37 in)
x 466 mm (18.35 in)
x 535 mm (21.06 in)
Ground Strap Length 305 cm (10 ft)
Suction/Return Hose Length 244 cm (8 ft)
Discharge/Pressure Hose Length 244 cm (8 ft)
(3) Discharge/Pressure Hose. (6) 9U-6978 Five Micron Weight 13.3 kg (29.30 lbs)
Filter Element. (7) Diaphragm Pump.
8
Operation Section 3. Connect a pressure air supply hose (dealer
supplied) to a regulated pressure air
Set-Up supply, and route the pressure hose to the
portable filtration unit.
1. Apply Teflon tape to threads and install a
male pressure air quick disconnect fitting
(dealer supplied) into the air inlet port on NOTE: To extend diaphragm pump life, the
the diaphragm pump. Tighten the fitting pressure air supply should be filtered and
securely. lubricated.
Pressure Air Quick Disconnect Fitting. Filtered and Lubricated Pressure Air Supply.
9
Connect Grounding Strap 2. Connect green ground strap clamp to the
machine being serviced, or other
WARNING component(s), that will come in contact
with the filter cart.
The portable diesel fuel
system filtration unit is
capable of producing NOTE: The ground strap connection must be
static electricity. The to bare metal to ensure proper grounding.
filtration unit must always be grounded to
the machine, with the supplied ground strap,
prior to making any fuel system
connections. Static electricity (sparks) can
cause a fire, resulting in serious injury or
death.
10
Fill Reservoir Tank Use the following procedure to fill the reservoir
tank with up to 18.9 L (5 gal.) of fresh, clean
WARNING diesel fuel.
1. Connect the green ground strap from the
Only adequately trained and filtration unit to the diesel fuel supply.
instructed personnel should be
authorized to operate the portable
diesel fuel system filtration unit. NOTE: The ground strap connection must be
to bare metal to ensure proper grounding.
Operators should be aware that
dangers exist when using the portable
diesel fuel system filtration unit and
related attachments. Improper
procedures create risk for the operator and
bystanders. DO NOT operate the filter cart until
checking to make sure no one will be
endangered.
Inspect all component parts of this
tool before each daily use. Check
for damage or excess wear on any
part. Replace all damaged or worn
parts immediately. Never operate equipment
with a known malfunction or leak.
2. Remove the filler cap from the top of the
The portable diesel fuel reservoir tank.
system filtration unit is
capable of producing a. Lift the filler cap T handle to a vertical
static electricity. The position.
filtration unit must always be grounded to
the machine, with the supplied ground strap,
prior to making any fuel system
connections. Static electricity (sparks) can
cause a fire, resulting in serious injury or
death.
11
b. Twist the T handle a quarter turn 4. Reinstall the filler cap on the reservoir tank.
counterclockwise to unlock the filler Turn the T handle clockwise a quarter turn
cap. and push the T handle down to lock the
cap.
12
Kidney Loop Reservoir Tank 2. Regulate the pressure air supply between
138 and 276 kPa (20.0 to 40.0 psi).
WARNING
The portable diesel fuel
system filtration unit is
capable of producing
static electricity. The
filtration unit must always be grounded to
the machine, with the supplied ground strap,
prior to making any fuel system
connections. Static electricity (sparks) can
cause a fire, resulting in serious injury or
death.
Pressure up to 345 kPa
(50.0 psi) can be trapped
in the diesel fuel system NOTE: To extend diaphragm pump life, the
filtration unit and related pressure air supply should be filtered and
components. Use caution when lubricated.
disconnecting hoses or fittings. Pressure
that is released can cause fuel spray.
3. To start the diaphragm pump, connect a
pressure air supply hose to the inlet air
Use this procedure to clean the diesel fuel in supply fitting.
the reservoir tank by kidney looping the fuel
through the five micron filter element.
13
4. Allow the diaphragm pump to circulate the Kidney Loop Fuel System
diesel fuel through the reservoir tank and
five micron filter elements until the Use this procedure to circulate diesel fuel from
recommended level of cleanliness is the engine fuel system through the filtration
achieved. unit filter element and reservoir tank.
Contaminated diesel fuel is combined with the
clean fuel in the reservoir tank and
NOTE: Initially, an S·O·S automatic particle continuously circulated through the fuel
counter should be used to verify the system, filter element, and reservoir tank to
cleanliness of the diesel fuel in the reservoir flush out and clean the engine fuel system.
tank. After the initial verification, periodic
audits should be performed to assure WARNING
continued performance to meet cleanliness
specifications. Samples are taken at S·O·S High pressure in excess of
port (12). 137,900 kPa (20,000.0 psi)
can be trapped in the
engine fuel injection
system and related components. To avoid
personal injury or death, always follow
specific engine guidelines to purge the fuel
system of any pressure.
Leaking fluid that is under
pressure can penetrate
body tissue. Fluid
penetration can cause
serious injury and possible death. A pin hole
leak can cause severe injury. If fluid is injected
into your skin, you must obtain treatment
(12) S·O·S Port. immediately. Seek treatment from a doctor
that is familiar with this type of injury.
5. Once the desired level of cleanliness is The portable diesel fuel
reached, stop the diaphragm pump by system filtration unit is
disconnecting the pressure air supply at capable of producing
the pressure air inlet fitting. static electricity. The
filtration unit must always be grounded to
the machine, with the supplied ground strap,
prior to making any fuel system
connections. Static electricity (sparks) can
cause a fire, resulting in serious injury or
death.
Pressure up to 345 kPa
(50.0 psi) can be trapped
in the portable diesel fuel
system filtration unit and
related components. Use caution when
disconnecting hoses or fittings. Pressure
that is released can cause fuel spray.
14
1. Connect the green ground strap clamp 4. Connect the adapter end (dealer supplied)
from the filtration unit to the machine. of suction/return hose (4) to the union block
on the high-pressure fuel pump.
15
6. Regulate the pressure air supply between 8. Allow the diaphragm pump to circulate the
138 and 276 kPa (20.0 to 40.0 psi). diesel fuel through the fuel system,
reservoir tank, and filter element until the
recommended level of cleanliness is
achieved.
16
WARNING Empty Reservoir Tank
Use this procedure to pump out the diesel fuel
Pressure up to 345 kPa from the reservoir tank. Fuel is pumped from
(50.0 psi) can be trapped the bottom of the reservoir tank, through the
in the diesel fuel system five micron filter, and out the
filter cart and related discharge/pressure hose.
components. Use caution when
disconnecting hoses or fittings. Pressure WARNING
that is released can cause fuel spray.
The portable diesel fuel
system filtration unit is
11. Disconnect the suction/return hose from capable of producing
the engine fuel system. static electricity. The
12. Disconnect the discharge/pressure hose filtration unit must always be grounded to
from the engine fuel system. the machine, with the supplied ground strap,
prior to making any fuel system
connections. Static electricity (sparks) can
NOTE: All substances and materials used cause a fire, resulting in serious injury or
with or on the diesel fuel system filtration unit death.
must be handled and disposed of properly.
This is very important when working with fuels.
Follow all Federal, State, and local regulations 1. Connect green ground strap clamp from
on disposal of waste products. the filter cart to an approved external fuel
tank or container.
17
2. Install a dealer-supplied, approved pump 4. To start the diaphragm pump, connect a
nozzle or ON/OFF valve in place of the fuel pressure air supply hose to the inlet air
system fitting on the engine end of the supply fitting.
discharge/pressure hose.
WARNING
Pressure up to 345 kPa
(50.0 psi) can be trapped
in the diesel fuel system
filter cart and related
components. Use caution when
disconnecting hoses or fittings. Pressure
that is released can cause fuel spray.
18
7. Disconnect ground strap (5) from the Maintenance Section
external fuel tank or container and neatly
coil it up.
WARNING
Inspect all component parts of this
tool before each daily use. Check
for damage or excess wear on any
part. Replace all damaged or worn
parts immediately. Never operate equipment
with a known malfunction or leak.
Pressure up to 345 kPa
(50.0 psi) can be trapped
in the diesel fuel system
filter cart and related
components. Use caution when
(5) Ground Strap. disconnecting hoses or fittings. Pressure
that is released can cause fuel spray.
Clean up all leaked or
NOTE: Only disconnect the ground strap after spilled fluids immediately.
all other connections between the filter cart Diesel fuel leaked or
and external fuel tank or container have been spilled onto any hot
removed. surfaces or electrical components can cause
a fire, resulting in personal injury or death.
MS
Always follow
M SD
SSS
M
M SSS
DDD c h e m i c a l
manufacturers
instructions for
proper handling of diesel fuel. Diesel fuel
exposed to open flame or sparks can cause
a fire, resulting in personal injury or death.
To avoid contact
with diesel fuel,
always wear
protective
glasses or face shield and protective
clothing, when servicing filters or other
components.
19
Inspection Filter Elements
Inspect the 295-5490 Portable Diesel Fuel Replace the filter element on a periodic basis,
System Filtration Unit before each daily use. or whenever the service filter gauge located
Replace all damaged or worn parts before on filter housing indicates service is required.
operating the filtration unit.
20
2. Use a 162-8872 S·O·S Sample Tube, and a 4. Slowly unthread filter element (6) and allow
small container, to release any fluid excess diesel fuel to drain into container.
pressure in the filtration unit.
WARNING
To avoid contact
with diesel fuel,
always wear
protective
glasses or face shield and protective
clothing, when servicing filters or other
components.
21
6. Lubricate the new filter gasket with clean oil Cleaning and Storage
and install it in the groove in filter housing.
Thread new filter element (6) onto the filter 1. Wipe up any fluids that accumulate in the
housing and hand-tighten it against the base tray.
filter housing gasket. 2. Wipe off hose quick disconnect fittings, and
install dust caps after every use.
3. Wipe down the diesel fuel system filtration
unit with a non-solvent based cleaner.
4. Coil up hoses and store the diesel fuel
system filtration unit indoors in a clean, dry
location.
22
Service Parts
11
10
8
3 9
4
5 6
1
0989-01
23
For information on service tools or shop supplies,
contact Dealer Service Tools on: