Instruction Manual

Cat. Nos. 0640, 0641, 0642, 0643, 0680, 0681, 0682, 0683, 0690 & 0691
Series Sealed Cap, Fuel Fills for EPA Fuel Systems
Installation and Operation Instructions
PLEASE READ ALL INSTRUCTIONS BEFORE PROCEEDING
These fills meet the new CARB and EPA requirements of U.S.C.G. Safety Standards (July 31, 2011) for 40
CFR Parts 9, 60, 80 et al. Control of Diurnal Emissions From Nonroad Spark-Ignition Engines and
Equipment.
WARNING: Do not attempt to use these non-vented EPA caps and/or fill and cap assemblies on older
vented non EPA certified boats. Cap and fill body
threads on the sealed non-vented EPA
fills have been changed and are incompatible with older style vented fills
.
Note: The vent line on the EPA fill functions only when the cap is removed and during the actual
filling process. Inspect the fill components annually for signs of wear. The system will not
seal properly if o-ring in cap is cracked or worn.
1. Select mounting location:
- In accordance with A.B.Y.C., U.S. Coast Guard and E.P.A. requirements and regulations.
- Surface must be flat and provide adequate clearance to remove the cap.
- Allow for adequate clearance under fill for routing fill and vent hose, which must be selected and installed in
accordance with A.B.Y.C. requirements and U.S. Coast Guard Safety Standards for Small Boat Fuel Systems
(33 CFR 183).
2. Attach mounting template to selected mounting surface and orient for desired position of fill/vent connections
and for ease of insertion of the fuel nozzle into the fill neck. Drill where indicated. Be sure to drill the 3/4 inch
hole before drilling the 2-1/16 inch hole.
NOTE: The 2-1/16” dimension of the larger hole is sized to provide mounting surface support to the fill
body. DO NOT use larger size cutter or drill.
3. Mount fill using #8 pan head screws. Caulk if necessary.
4. Attach and clamp 1-1/2 inch fill hose and 5/8 inch vent hose in accordance with the above referenced
standards.
NOTE: Plastic fuel fills should NOT
be grounded.
(1). American Boat & Yacht Council, Inc. (2). U.S. Coast Guard (3). E.P.A.
3069 Solomanʼs Island Rd. Washington, D.C. 20593 401 “M” Street S.W.
Edgewater, Maryland 21307 (or your local C.G. office) Washington, D.C. 20460
04/11
0640INS1
Drill 3/4” Dia. Hole
(Drill First)
1-7/32”
Drill for #8 Size Mounting Screws
4 Places (Drill Last)
Drill 2-1/16” Dia. Hole
(Drill Second)
See Note after instruction #2
MOUNTING TEMPLATE
PERKO, INC.
16490 N.W. 13th Avenue
Miami, FL 33169-5707
www.perko.com
Cat. Nos. 0640, 0641, 0642, 0643, 0680, 0681, 0682, 0683, 0690 & 0691
Series Sealed Cap, Fuel Fills for EPA Fuel Systems
Installation and Operation Instructions
PLEASE READ ALL INSTRUCTIONS BEFORE PROCEEDING
These fills meet the new CARB and EPA requirements of U.S.C.G. Safety Standards (July 31, 2011) for 40
CFR Parts 9, 60, 80 et al. Control of Diurnal Emissions From Nonroad Spark-Ignition Engines and
Equipment.
WARNING: Do not attempt to use these non-vented EPA caps and/or fill and cap assemblies on older
vented non EPA certified boats. Cap and fill body
threads on the sealed non-vented EPA
fills have been changed and are incompatible with older style vented fills
.
Note: The vent line on the EPA fill functions only when the cap is removed and during the actual
filling process. Inspect the fill components annually for signs of wear. The system will not
seal properly if o-ring in cap is cracked or worn.
1. Select mounting location:
- In accordance with A.B.Y.C., U.S. Coast Guard and E.P.A. requirements and regulations.
- Surface must be flat and provide adequate clearance to remove the cap.
- Allow for adequate clearance under fill for routing fill and vent hose, which must be selected and installed in
accordance with A.B.Y.C. requirements and U.S. Coast Guard Safety Standards for Small Boat Fuel Systems
(33 CFR 183).
2. Attach mounting template to selected mounting surface and orient for desired position of fill/vent connections
and for ease of insertion of the fuel nozzle into the fill neck. Drill where indicated. Be sure to drill the 3/4 inch
hole before drilling the 2-1/16 inch hole.
NOTE: The 2-1/16” dimension of the larger hole is sized to provide mounting surface support to the fill
body. DO NOT use larger size cutter or drill.
3. Mount fill using #8 pan head screws. Caulk if necessary.
4. Attach and clamp 1-1/2 inch fill hose and 5/8 inch vent hose in accordance with the above referenced
standards.
NOTE: Plastic fuel fills should NOT
be grounded.
(1). American Boat & Yacht Council, Inc. (2). U.S. Coast Guard (3). E.P.A.
3069 Solomanʼs Island Rd. Washington, D.C. 20593 401 “M” Street S.W.
Edgewater, Maryland 21307 (or your local C.G. office) Washington, D.C. 20460
04/11
0640INS1
Drill 3/4” Dia. Hole
(Drill First)
1-7/32”
Drill for #8 Size Mounting Screws
4 Places (Drill Last)
Drill 2-1/16” Dia. Hole
(Drill Second)
See Note after instruction #2
MOUNTING TEMPLATE
PERKO, INC.
16490 N.W. 13th Avenue
Miami, Fl. 33169-5707
www.perko.com