793d Off-Highway Truck Fdb00001-Up (Machine) Powered by 3516b Engine (Sebp3976 - 206) - Systems & Components

7/4/2019 793D Off-Highway Truck FDB00001-UP (MACHINE) POWERED BY 3516B Engine(SEBP3976 - 206) - Systems & Components
Previous Screen
Welcome: r080crc15
Product: TRUCK
Model: 793D TRUCK FDB
Configuration: 793D Off-Highway Truck FDB00001-UP (MACHINE)
POWERED BY 3516B Engine
Tool Operating Manual

20 GPM Portable Fuel Filtration System {0374, 0599, 0706, 1250, 1256, 1261}
Media Number -NEHS1216-01 Publication Date -19/08/2015 Date Updated -02/11/2018
i07152872
20 GPM Portable Fuel Filtration System {0374, 0599, 0706, 1250,

1256, 1261}
SMCS - 0374; 0599; 0706; 1250; 1256; 1261
Caterpillar Products
All
Introduction
Important Safety Information
European Union Compliant, CE, and WEEE marked
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.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&calledpag… 1/19
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
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
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.
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
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
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 75 L/min (20 GPM).
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
International: 1-309-578-7372
Nomenclature
Table 1
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
Table 2
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
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
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.
NOTICE
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
1. Connect the battery cables on the cart to the 12 VDC power supply.
2. Remove dispensing nozzle from the nozzle boot.
3. Move the switch lever to the "ON" position to power the pump.
4. Insert the dispensing nozzle into the container to be filled.
5. 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.
6. Operate the nozzle to dispense fluid. Release nozzle when the desired amount of fluid has been dispensed.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&calledpa… 10/19
7. Move the switch lever to the "OFF" position to turn off the pump.
8. 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.
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
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.
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:
1. Disconnect power to the unit.
2. Open the vent valve on the cover of the housing. Allow the unit to thoroughly vent before opening the
cover.
3. Open the drain plug or drain valve on the housing bottom. Allow all fluid to drain from the unit.
4. Loosen swing bolts, then remove the housing body and element.
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.
5. Remove and discard the expended cartridge and closure o-ring in a FIRE-SAFE place.
6. 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
7. Remove a new filter element from the shipping carton. Closely inspect the element before installing. Slide
the new element into the housing.
8. 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).
9. Close the drain plug or valve on the bottom of the housing.
10. 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.
11. Leave the vent valve on top of the unit open, to allow entrapped air to escape while filling
12. When a small amount of fluid flows from the vent , close the vent tightly
13. During initial filling, after above maintenance, and while unit is in operation, examine housing and all
connections for leaks.
14. 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
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
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

Table 3
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.
Table 4
Troubleshooting Chart
Symptom Cause Cure
Check for leaks or obstructions in
Suction line problem
suction line
Remove and inspect valve; must move
Bypass valve open
freely and be free of debris.
Check vanes and slots for nicks, burrs,
Vanes sticking
Pump will not prime and wear.*
Inspect rotor and vans for excessive

Excessive rotor or vane wear
wear or damage. Replace if necessary.*
Reduce vertical and horizontal distance
Vapor lock from pump to liquid. Remove automatic
nozzle.
Excessive dirt in screen Remove and clean screen.
Check suction line for leaks or
Suction line problem restrictions. It may be too small, too long
or not airtight.
Remove and inspect valve. Valve must
Bypass valve sticking
move freely and be free of debris.
Check pump outlet, hose, nozzle, and

Outlet blocked
Low capacity filter for blockage.
Vanes sticking Check vanes and slots for 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 Check incoming line voltage while pump

Incorrect voltage
is running.
Inspect vanes and slots for nicks, burrs,
Vanes sticking
and wear.*
Wiring problem Check for loose connections.
Motor problem Return to place of purchase.
Remove and inspect valve. Valve must be

Bypass valve sticking
free of debris.
Motor stalls/ fuse blows or Check incoming line voltage while pump
Low voltage
thermal protector trips is running.
repeatedly Check rotor and vanes for excessive
wear and damage.*
Debris in pump cavity Clean debris from pump cavity.
These fluids can only be pumped for
Pumping high viscosity
short periods of time. (Less than 30
fluids
minutes duty cycle)
Clogged screen Remove and clean screen.
Motor overheats
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.
No power Check incoming power
Switch failure Replace switch (KIT120SW)
Motor inoperative Motor failure Return to place of purchase.
Thermal protector failure Return to place of purchase.

Incorrect loose wiring Check wiring.
Bad O-Ring gasket Check all O-Ring gaskets.
Dirty shaft seal Clean seal and seal cavity.
Bad shaft seal Replace seal
Fluid leakage
Refer wetted parts list to fluid
Incompatible fluid
manufacturer.
Loose fasteners Tighten fasteners.
Pump hums but will not Motor failure Return to place of purchase.
operate Broken rotor key. Remove all debris and replace key.
Inlet or outlet valve is

Completely open inlet/outlet valve.
closed.
Straighten hose and/or provide larger
Fuel hose is kinked.
No fuel flow. hose.
Differential pressure gage
reading greater than 15.0 psi Replace filter element and clean vessel.
(103.4 kPa)
Differential gage reading Damaged or ruptured filter Check filter element, and change as
suddenly drops. element. needed.
Note: All repairs marked with an asterisk (*) may require a new Pump (Part No. 464-8512).
NOTICE
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
Copyright 1993 - 2019 Caterpillar Inc. Sun Apr 07 2019 16:21:16 GMT-0500 (hora estándar de Perú)
All Rights Reserved.
r080crc15
Private Network For SIS Licensees.

793d Off-Highway Truck Fdb00001-Up (Machine) Powered by 3516b Engine (Sebp3976 - 206) - Systems & Components

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

793d Off-Highway Truck Fdb00001-Up (Machine) Powered by 3516b Engine (Sebp3976 - 206) - Systems & Components

Hochgeladen von

Copyright:

Verfügbare Formate

7/4/2019 793D Off-Highway Truck FDB00001-UP (MACHINE) POWERED BY 3516B Engine(SEBP3976 - 206) - Systems & Components

Tool Operating Manual

20 GPM Portable Fuel Filtration System {0374, 0599, 0706, 1250,

European Union Compliant, CE, and WEEE marked

General Information Section

Service Parts Section

Safety Icon Nomenclature

Personal Protection/Important Information

Crushing Hazard (foot)

Crushing Hazard (hand)

Electrical Shock - Hazard

At operating temperature, the hydraulic tank is hot and under pressure.

Always use a board or cardboard when checking for a leak.

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

The system is powered by an onboard 12V DC pump.

Information Release Memo, PELJ1706, "Portable Bulk Fuel Filtration System"

Publication: PEHJ0156 "Bulk Fuel Filtration"

Service Manual, SEBU6250, "Caterpillar Machine Fluid Recommendations"

Additional Contact Information

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

1 1 464-8511 Mounting Bracket

4 1 461-5138 Filter Housing Assembly

6 1 6V-0852 Dust Cap

Item Part No Qty

Note: The O-ring is provided with replacement elements.

2. Remove dispensing nozzle from the nozzle boot.

4. Insert the dispensing nozzle into the container to be filled.

Water Sight Glass

1. Disconnect power to the unit.

9. Close the drain plug or valve on the bottom of the housing.

Filter Element Replacement

Service Repair Parts

2 1 464-8512 Pump (12V)

7 1 8T-0863 Pressure Gage

Inspect rotor and vans for excessive

Check pump outlet, hose, nozzle, and

Pump runs slowly Check incoming line voltage while pump

Wiring problem Check for loose connections.

Motor problem Return to place of purchase.

Remove and inspect valve. Valve must be

Motor failure Return to place of purchase.

Thermal protector failure Return to place of purchase.

Inlet or outlet valve is

Das könnte Ihnen auch gefallen