R

NEHS0989
July 2006

TOOL
OPERATING
MANUAL
295-5490 Portable Diesel Fuel System
Filtration Unit

European Union Compliant, CE marked

SMCS: 0684
Important Safety Information
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
operation, lubrication, maintenance, and
repair information.
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.
WARNING
The meaning of this safety alert symbol is as
follows:
Attention! Become Alert! Your Safety is
Involved.
2
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
used, you must satisfy yourself that it is
safe for you and for others. You should
also ensure that the product will not be
damaged or be made unsafe by the
operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations
in this publication are on the basis of
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.
WARNING
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.
Failure to heed this warning can lead to
premature failures, product damage,
personal injury, or death.
Contents
Literature Information
Safety Section . . . . . . . . . . . . . . . . . . . . . . . 3
General Information Section . . . . . . . . . . . . 3
Operation Section . . . . . . . . . . . . . . . . . . . . 3
Maintenance Section . . . . . . . . . . . . . . . . . . 3
Safety Section
Safety Icon Nomenclature . . . . . . . . . . . . . . 4
Personal Protection/Important Information 4
Prohibited Action . . . . . . . . . . . . . . . . . . . . 4
Hazard Avoidance . . . . . . . . . . . . . . . . . . . 4
Safety Warnings Section. . . . . . . . . . . . . . . 4
Personal Protection/Important Information . 4
Hazard Avoidance . . . . . . . . . . . . . . . . . . . . 5
Machine Operation Hazards . . . . . . . . . . . . 5
Fluid Penetration . . . . . . . . . . . . . . . . . . . . . 6
Parts Replacement . . . . . . . . . . . . . . . . . . . 6
Intended Usage . . . . . . . . . . . . . . . . . . . . . . 6
Warning Films . . . . . . . . . . . . . . . . . . . . . . . 6
General Information Section
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Contact Information . . . . . . . . . . 7
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . 8
Specifications. . . . . . . . . . . . . . . . . . . . . . . . 8
Operation Section
Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connect Grounding Strap . . . . . . . . . . . . . 10
Fill Reservoir Tank . . . . . . . . . . . . . . . . . . . 11
Kidney Loop Reservoir Tank . . . . . . . . . . . 13
Kidney Loop Fuel System . . . . . . . . . . . . . 14
Empty Reservoir Tank . . . . . . . . . . . . . . . . 17
Maintenance Section
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 19
Filter Elements . . . . . . . . . . . . . . . . . . . . . . 20
Cleaning and Storage . . . . . . . . . . . . . . . . 22
Service Parts . . . . . . . . . . . . . . . . . . . . . . . 23
3
Literature Information
This manual should be stored with the tool
group.
This manual contains safety information,
operation instructions, and maintenance
information.
Some photographs or illustrations in this
publication 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, please 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. It 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 its capabilities.
Maintenance Section
The Maintenance section is a guide to
equipment care.
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
DS S
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.

Safety alert symbol

Slipping hazard

Tripping hazard

4
Hazard Avoidance Machine Operation Hazards
WARNING WARNING
MS
Always consult the Material Safety Only adequately trained and
M SD
SSS
M
M SSS
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.

MS
Always follow Inspect all component parts of this
M SD
SSS
M
M SSS
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.

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.
Failure to heed this warning can lead to
premature failures, product damage,
personal injury, or death.
Intended Usage
WARNING
This tooling should never be used
for any other application other than
its intended use; Filtering diesel
fuel in Caterpillar Equipment diesel
fuel systems. Using this tooling for any other
purpose can result in serious injury or even
death.
WARNING
Bodily Injury Hazard
Fire and Explosion Hazard
To reduce risk of serious injury:
• Dispose of exhaust air safely. If diaphragm
ruptures, fluid will be exhausted with air.
• Equipment must be grounded.
• Before servicing, relieve fluid pressure.
• Always wear protective eye wear.
• Fluid must be compatible with pump.
• Read instruction manual before operating.
Additional warning films may be required in
your area. Check local, state, and federal
regulations for proper display of warning films
for the fluids being filtered.

6
General Information Section
Introduction
The 295-5490 Portable Diesel Fuel System
Filtration Unit cleans diesel fuel systems by
removing contaminants in the fuel. This fuel
system filtration unit combines an air powered
diaphragm pump with a five micron filter
element in a compact, lightweight portable
package.
295-5490 Diesel Fuel System Filtration Unit.
The portable diesel fuel system filtration unit
should be used to clean the diesel fuel system
before engine re-start, or after replacement of
a failed fuel system component. It can also be
used to ensure the cleanliness of a fuel system
when the condition of the fuel in the system, or
specific components, is not known.
The filtration unit can clean the diesel fuel
within the reservoir tank, and then, once
connected to the engine fuel system, kidney
loop fuel through the filter element, reservoir
tank, and engine fuel system until the desired
level of cleanliness is achieved.
7
Initially, an automatic particle counter should
be used to verify the cleanliness of the diesel
fuel in the reservoir tank and/or the engine fuel
system. After the initial verification, periodic
audits should be performed to assure
continued performance to meet cleanliness
specifications.
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.
Additional Contact Information
For additional product support questions
concerning this tool, contact the Caterpillar
Dealer Service Tools Hotline at:
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1355
dealerservicetool_hotline@cat.com
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) Reservoir to Pump Hose. (9) Pressure Air Inlet Fitting.

(10) 345 kPa (50.0 psi) Pressure Relief Valve.
(11) Pressure Air Exhaust Muffler.

8
Operation Section
Set-Up
1. Apply Teflon tape to threads and install a
male pressure air quick disconnect fitting
(dealer supplied) into the air inlet port on
the diaphragm pump. Tighten the fitting
securely.
Pressure Air Quick Disconnect Fitting.
2. Position the portable diesel fuel system
filtration unit near the work site.
NOTE: A two wheel dolly can be used to
transport the filtration unit to the required
location.
Two wheel dolly used to transport filtration unit.
9
3. Connect a pressure air supply hose (dealer
supplied) to a regulated pressure air
supply, and route the pressure hose to the
portable filtration unit.
NOTE: To extend diaphragm pump life, the
pressure air supply should be filtered and
lubricated.
Filtered and Lubricated Pressure Air Supply.
NOTICE
The diaphragm pump can start whenever a
pressure air supply is connected to the inlet
pressure air fitting. To avoid unintended
pumping, do not connect the pressure air supply
until all other connections are complete.
NOTE: The diaphragm pump requires a
minimum air supply pressure of 138 kPa
(20.0 psi) to function. Higher pressure up to
276 kPa (40.0 psi) may be used, but is not
generally required.
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.

Always make sure there is a secure ground

strap connection between the portable diesel
fuel system filtration unit and the machine or
other component before performing any other
steps.
1. Uncoil green ground strap (5).

(5) Ground Strap.

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.

c. Lift the filler cap from the top of the

reservoir tank. 5. Disconnect ground strap (5) from the diesel
fuel supply and neatly coil it up.

(5) Ground Strap.

NOTE: If the filler cap becomes difficult to
remove and install, apply a small amount of
grease to the rubber seal.
NOTE: Only disconnect the ground strap after
all other connections between the filtration unit
and diesel fuel supply have been removed.
3. Fill the reservoir tank with clean diesel fuel
until the fuel is just above the level of the
return hose connection on the front of the
reservoir.

NOTE: The reservoir tank has a maximum

capacity of 18.9 L (5 gal). Do not over fill the
tank.

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.

1. Connect the suction/return and

discharge/pressure hose quick disconnect
fittings together, as shown.

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.

NOTE: The ground strap connection must be

to bare metal to ensure proper grounding. NOTE: For additional information, refer to
Procedure for Filtering the Fuel System manual
for the specific engine being serviced.

2. Before connecting filter cart hoses, make

(4) Suction/Return Hose.
sure any pressure trapped in the engine
fuel system has been released and that the
temperature of the fuel is at a safe level.
5. Connect the adapter end (dealer supplied)
of discharge/pressure hose (3) to the fuel
system low pressure drain line on the
NOTE: For additional information, refer to
engine.
Procedure for Filtering the Fuel System manual
for the specific engine being serviced.
NOTE: For additional information, refer to
Procedure for Filtering the Fuel System manual
3. To prepare the engine fuel system for
for the specific engine being serviced.
flushing, install flushing injectors and
flushing flow limiters.

NOTE: For additional information, refer to

Procedure for Filtering the Fuel System manual
for the specific engine being serviced.

(3) Discharge/Pressure Hose. (12) Reservoir To Pump

Supply Hose. (13) Pump To Filter Housing Hose.

15
6. Regulate the pressure air supply between
138 and 276 kPa (20.0 to 40.0 psi).
7. To start the diaphragm pump, connect a
pressure air supply hose to the inlet air
supply fitting.
NOTE: To extend diaphragm pump life, the
pressure air supply should be filtered and
lubricated.
16
8. Allow the diaphragm pump to circulate the
diesel fuel through the fuel system,
reservoir tank, and filter element until the
recommended level of cleanliness is
achieved.
9. The use of a particle counter is
recommended throughout the cleaning
process. Samples are taken at S·O·S port
(12).
NOTE: Initially, an S·O·S automatic particle
counter should be used to verify the
cleanliness of the fuel in the diesel fuel system.
After the initial verification, periodic audits
should be performed to assure continued
performance to meet cleanliness
specifications.
(12) S·O·S Port.
10. Once the desired level of cleanliness is
reached, stop the diaphragm pump by
disconnecting the pressure air supply
hose from the pressure air inlet fitting.
 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.

13. Disconnect ground strap (5) from the

machine and neatly coil it up. NOTE: The grounding strap connection must
be to bare metal to ensure proper grounding.

(5) Ground Strap.

NOTE: Only disconnect the ground strap after

all other connections between the filter cart
and engine fuel system have been removed.

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.

NOTE: The diaphragm pump will not operate

until the ON/OFF valve or nozzle is opened.

9U-7449 Pump Nozzle.

3. Regulate the pressure air supply between

138 and 276 kPa (20.0 to 40.0 psi).
5. Use the nozzle or valve on the end of the
discharge/pressure hose to dispense the
fuel from the reservoir tank into an
approved external fuel tank or container.

6. Once the reservoir tank is empty, close the

ON/Off valve or nozzle and disconnect the
pressure air supply hose.

NOTE: Diaphragm pump pulses will quicken

once all available fuel is pumped from the
reservoir tank.

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
Inspect the 295-5490 Portable Diesel Fuel
System Filtration Unit before each daily use.
Replace all damaged or worn parts before
operating the filtration unit.
NOTE: Carefully inspect the green grounding
strap. Make sure the connections at the
diaphragm pump and filler cap are secure and
the ground strap is in good condition.
20
Filter Elements
Replace the filter element on a periodic basis,
or whenever the service filter gauge located
on filter housing indicates service is required.
NOTE: All substances and materials used
with or on the diesel fuel system filtration unit
must be handled and disposed of properly.
This is very important when working with fuels.
Follow all Federal, State, and local regulations
on disposal of waste products.
1. Prior to replacing the filter element,
complete the following steps, as necessary.
a. To avoid diesel fuel spills, make sure
the level of diesel fuel in the reservoir is
below the level of the filter housing.
NOTE: If necessary, follow the steps in the
Empty Reservoir Tank section in this manual to
remove fuel from the reservoir tank.
b. To avoid diesel fuel spills, make sure
the discharge/pressure hose and
suction/return hose are not connected
to any external tank or machine.
c. To avoid diesel fuel spills, make sure a
pressure air supply is not connected to
the diaphragm pump.
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.

NOTE: The 162-8872 S·O·S Sample Tube is

available as part of the 177-9343 Cap Group.
For more information, contact Dealer Service
Tools.

NOTE: All substances and materials used

with or on the diesel fuel system filtration unit
must be handled and disposed of properly.
This is very important when working with fuels.
Follow all Federal, State, and local regulations
on disposal of waste products.

5. Remove the old filter element and old

gasket. Empty any diesel fuel into the
container and dispose of the filter and
gasket properly.

NOTE: The old gasket may stay attached to

the groove of the filter housing on the diesel
fuel filtration unit. Make sure it is removed
before installing the new filter and gasket.
162-8872 S·O·S Sample Tube Used To Release Pressure.

3. Place a suitable container under the filter to

catch excess diesel fuel.

WARNING
To avoid contact
with diesel fuel,
always wear
protective
glasses or face shield and protective
clothing, when servicing filters or other
components.

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6. Lubricate the new filter gasket with clean oil
and install it in the groove in filter housing.
Thread new filter element (6) onto the filter
housing and hand-tighten it against the
filter housing gasket.
Cleaning and Storage
1. Wipe up any fluids that accumulate in the
base tray.
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.

(6) Five Micron Filter Element.

7. Carefully remove the container from under

the filter element and properly dispose of
the diesel fuel.

NOTE: All substances and materials used

with or on the diesel fuel system filtration unit
must be handled and disposed of properly.
This is very important when working with fuels.
Follow all Federal, State, and local regulations
on disposal of waste products.

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Service Parts

11
10
8

3 9

4
5 6

1
0989-01

295-5490 Portable Diesel Fuel Filtration Unit Repair Kits

Item Qty. Part No. Description Part No. Description
1 1 CP-3101 Tray 295-5591 Diaphragm Pump Repair Kit
2 1 268-1582 Coupler 295-5590 Air Valve Repair Kit
3 1 295-8468 Dust Cap
4 1 268-1583 Coupler
5 1 295-8469 Dust Cap
6 1 295-5592 Pump
7 1 9U-6986 Gauge
8 1 9U-6987 Filter Head
9 1 9U-6978 Filter Element
10 1 183-3873 Breather
11 1 7X-3387 S·O·S Valve

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 For information on service tools or shop supplies,
contact Dealer Service Tools on:

Dealer Service Tools

501 S. W. Jefferson
Peoria, IL U.S.A. 61630-2125
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1355
dealerservicetool_hotline@cat.com

©2006 Caterpillar NEHS0989

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All Rights Reserved Printed in U.S.A.