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Information Release Memo

MP06-02

October 2006

Cat® Maintenance Products

FAST FILL FUEL KITS AVAILABLE FOR CATERPILLAR® EQUIPMENT Announcement Caterpillar is excited to offer a new non-pressurized fast fill fuel kit available for Caterpillar® equipment. The new fast fill fuel kits do not depend on a traditional pressure-sensing nozzle to shut off fuel flow, but instead rely on a valve to control fuel shut off. These kits are available for installation and can be ordered through the ANTARESSM parts ordering system. Kits can be used to retrofit existing pressurized fast fill systems or add to machines without fast fill provisions.

Illustration 1. Typical flange-mounted fuel receiver on new fast fill fuel systems.

For Dealer Sales Personnel The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and is intended exclusively for their information and training. Any reproduction of this release without the foregoing explanation is prohibited.

PELJ0713

Printed in USA

© 2006 Caterpillar All Rights Reserved

Information Release Memo

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Caterpillar Fast Fill Fuel System Kits Fast Fill Fuel System Kits Available Through Caterpillar Parts Ordering System (ANTARES) Table 1 Caterpillar Machine Models Supported by New Fast Fuel Kit Machine Type Machine Number Serial Number Prefix Off-highway 769D; 773E; 776D; BBB; BDA; AFS; AGC, Truck/Tractor 777D AGY 725; 730; 730 B1L, AFX; AGF, B1M; Articulated Truck EJECTOR; 735; 740; B1W; B1N, AWR; AXM, 740 EJECTOR B1P; B1R, AZZ BKF, BLY; EDA, KBC, 385B; 385C; 5090B; SBE, T2E, T2F, JCM, Excavator 5110B; 5130B MNZ; CLD, SJY; AAA, AAK, AAT; 4CS Quarry Truck 771D; 775E BCA; BEC BBN, 2KZ; BTW; A4W; Wheel Dozer 844; 844H; 854G; 814F BGF 980H; 988G; 988H; 990 JMS; BNH, 2TW; BXY; Wheel Loader Series II; 990H; 992G; BCR; BWX; AZX; 442; 994F; 994D 3TZ

Product Features and Benefits of the New Fast Fill Fuel System Kit • •

• •

Shut-Off Valve Leads to Elimination of Spills and Overflows Feedback Loop System Improves Contamination Control, Allows for Faster Fill Rates, and Improves Vent Durability Easier Receiver Replacement with Flange Mount Filtered Breathing Illustration 2. Refueling of a Caterpillar machine with the new fast fill fuel system

Information Release Memo

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Features and Benefits of the New Fast Fill Fuel Kit

Shut-Off Valve Leads to Elimination of Spills and Overflows The new fast fill fuel kits contain a non-pressurized system that uses a valve to control fuel shut off instead of tank pressure. Once this shut off valve is closed it cannot be forced open by the operator, preventing operators from “topping off” their fuel tanks to unsafe levels and eliminating inadvertent spills and overfilling. Even when holding the nozzle in the open position, additional fuel cannot be introduced. This feature: • • •

Eliminates fuel waste by preventing over-/under-filling of tank Minimizes fueling downtime by providing full tank with greater accuracy Increases compliance with environmental requirements

Feedback Loop System Improves Contamination Control, Allows for Faster Fill Rates, and Improves Vent Durability Along with keeping contaminants and other hazardous materials away from the fuel, the closed loop system allows for higher fuel fill rates of up to 454 liters (120 US gallons) per minute. • • •

Improves contamination control Operators can rapidly refill tanks and keep equipment in service Increases vent durability, resulting in lower replacement costs and less risk of fuel leaks and fuel contamination

Easier Receiver Replacement with Flange Mount The flange-mounted assembly allows for easy attachment of the fuel pipe to decrease the risk of damaging fuel tank port threads or causing fuel leaks. Also, split flanges can be removed with common service tools as opposed to the large wrench needed to replace threaded receivers, because less clearance is needed to split flange bolts. The flange mounted receiver design requires less clearance to loosen the flange bolts and replace the receiver. • • •

Fast, easy replacement and installation of receiver Reduces costs and maintenance time Previously, to service the receiver the fuel tank had to be drained. The nonpressurized fast fill system has a inlet check valve which reduces spillage and eliminates the need to drain the fuel tank for receiver servicing

Information Release Memo

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MP06-02

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Filtered Breathing The non-pressurized system uses a vacuum vented fuel cap for fuel consumption displacement. The vent in the fast fill system is normally closed except during refueling operations. Breathing through a 10 or 100 micron fuel cap filter keeps the fuel cleaner, reducing maintenance cost.

Illustration 3. Component diagram of fast fill fuel system

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Fast Fill Fuel Kit Consist The 285-1202 Fast Fill Fuel System Kits contain all parts necessary to successfully install a fast fill fuel system in your Caterpillar machine. See Table 2 for a complete listing of these parts. Note: it is imperative that the non-vented fuel cap on pressurized systems be replaced with the filter cap when using the non-pressurized system to allow for vacuum venting.

Table 2. Fast Fill Fuel Kit Components (see Illustration 3 for component diagram) 285-1202 Kit-Fast Fuel (Flange) PIN (S/N: BBB1-Up) Note

Reference Number

Illustration Number

Part Number

Qty

B

1

3

7X-7700

1

2 3 4 5 6 7

3 3 3 3 3 3

9D-0630 221-5303 221-5304 221-7693 224-2988 232-1767

1 1 1 1 1 1

8

3

105-3484

6

9 10 11 12 13 14 15

3 3 3 3 3 3 3

146-3338 1H-8128 1J-9671 1P-4582 4J-0527 5H-6734 5P-2618

2 1 2 2 1 1 2

16

3

6V-8200

4

17

3

8M-2772

1

18

3

8T-4121

12

19

3

8T-4136

6

20

3

8T-4223

4

M

M

M

Part Name CAP AS-FILLER (FUEL TANK) Or 164-4858 extreme cap CAP-DUST PLATE PLATE VALVE (FAST FILL FUEL) VENT AS RECEIVER AS (FAST FILL FUEL) BOLT-SOCKET HEAD (M10X1.5X25-MM) COUPLING-PERMANENT SEAL-O-RING SEAL-O-RING FLANGE-HALF SEAL-O-RING SEAL-O-RING CONNECTOR BOLT-SOCKET HEAD (M12X1.75X35-MM) CLIP WASHER-HARD (11X21X2.5-MM THK) BOLT (M10X1.5X25-MM) WASHER-HARD (13.5X25.5X3-MM THK) HOSE

A, E 21 3 224-7696 183 A – Not part of this group B – The 7X-7700 fuel tank cap must be installed with the fast fill system E – Order hose separately by the centimeter M – Metric part

Information Release Memo

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Publications These publications provide supplemental information on Caterpillar fast fill fuel systems as well as fuel caps.

Media #

Title

REHS3062-00

Fast Fill System – Fuel

PELJ0282

GU04-02 Kits Available to Convert Caterpillar Or Wiggins Fast Fuel System Threaded Receivers To Cat Flange Mounted Receivers

Information Release Memo

PELJ0566

GU05-01 Fuel Caps 00

Information Release Memo

PEHJ0053

Cat Fast Fuel System Conversion Kits Datasheet

Data Sheet

With filter

Type Special Instructions

Air flow

Illustration 4. A non-pressurized fast fill fuel system with empty tank (currently filling)

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Vent in closed position

Illustration 5. A non-pressurized fast fill fuel system with full tank

System Operation During filling (Illustration 4), a small amount of fuel passes through an orifice on the inlet side of the valve. The fuel flowing through the orifice fills the inside of the diaphragm, and then continues to flow up a signal line and out through the float shutoff valve in the level control vent and out into the tank. When the fuel level reaches the full tank level (Illustration 5), the float shutoff valve closes and fuel flow through the signal line is stopped. Fuel flowing through the orifice in the shutoff valve fills the pressure chamber behind the piston until the valve closes. The closed valve builds backpressure between the shutoff valve and the receiver, which causes the refueling nozzle to shut off. With the float in the up position (signal line valve closed), fuel can no longer be forced into the tank, preventing operators from “topping off” their fuel tanks to unsafe levels.

Information Release Memo

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Installation For more information on installing the 285-1202 Fast Fill Fuel System Kit, please reference Special Instruction REHS3062-00 for instructions. These special instructions are available through SIS Web and are included in every new fast fill fuel kit. Caterpillar fast fill fuel system kits allow dealers to improve sales of both parts and complete fuel systems for Caterpillar machines. Rely on Caterpillar’s innovative fast fuel system technology for improved performance, easier service, and cleaner environments.

Brandon L. Tomlinson Product Support Division General Usage Parts Product Division LC 2184 – (309) 675-1863 [email protected]

The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and is intended exclusively for their information and training. Any reproduction of this release without the foregoing explanation is prohibited. This IRM can be viewed and downloaded electronically from the Internet. Please refer to your marketing organization specific site for access to the Electronic Sales Library, which contains all of the active IRMs and product support communication materials. CAT, CATERPILLAR, ANTARES, their respective logos, "Caterpillar Yellow," and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. Electronic Sales Library Internal Caterpillar Employees – http://cds.cat.com/PSMprev.nsf/$$MediaNumber