New Tube Assembly for the Low-Pressure Fuel System on Certain C6.6 Machine Engines{1261, 1274} Caterpillar


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New Tube Assembly for the Low-Pressure Fuel System on Certain C6.6 Machine Engines{1261, 1274} [REHS3779]
FUEL SYSTEM
FILTER GP-FUEL
1.1. Introduction
2.1. Required Parts
3.1. Removal Procedure
4.1. Installation Procedure
Integrated Toolcarrier:
IT38H (S/N: JNJ530-UP)
Wheel Loader:
938H (S/N: MCC274-UP; MJC1065-1906,11874-UP; JKM1097-2309,3100-UP; LKM1149-2143,31958-UP)

Introduction

There have been isolated instances of issues with 353-3571 Filter Tube that are installed on certain C6.6 machine engines.


NOTICE

Do not perform any procedure that is outlined in this Special Instruction until you have read and understood the information that is contained in this document.



NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, General Hazard Information and High Pressure Fuel Lines for safety information. Refer to System Operation, Testing and Adjusting, Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.


Required Parts

Table 1
Required Parts    
Part Number     Part Description     Qty    
439-8115     Fuel Line     1    

Removal Procedure

Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A     278-4138     Fuel System Protection Gp     1    



    Illustration 1g03646083

    Tube assembly with plastic section incorporated between the two steel sections

  1. Turn the fuel supply to the OFF position.

  1. Turn the battery disconnect switch to the OFF position.



    Illustration 2g03722979

    Typical example




    Illustration 3g03722980

    Typical example

  1. Remove bolt (1) from the clip for tube assembly (6) .

  1. Remove nut (3) from the clip for tube assembly (6). Remove nut (2) from bolt (8) .

  1. If necessary, disconnect fuel injection line at fuel injection pump in order to improves access. Use Tooling (A) in order to plug the open port in fuel injection pump.

  1. Remove tube assembly (6) from fuel injection pump (16) and secondary fuel filer assembly (5) .

  1. Use Tooling (A) to cap the connection on secondary fuel filer assembly (5). Use Tooling (A) to cap the connection (15) on fuel injection pump.

  1. Disconnect tube assembly (9) from secondary fuel filer assembly (5) .

  1. Use Tooling (A) to cap the connection on secondary fuel filer assembly (5). Use Tooling (A) to plug the tube assembly (9) .

  1. Disconnect tube assembly (7) from secondary fuel filer assembly (5) .

  1. Use Tooling (A) to cap the connection on secondary fuel filer assembly (5). Use Tooling (A) to plug the tube assembly (7) .

  1. Remove bolt (11) from bracket (10). Remove spacer (12). Remove bracket (10). Remove tube assembly (7) from clip (17) .

  1. Remove bolts (8) for secondary fuel filer assembly (5). Remove spacer (4) from bracket (14). Remove secondary fuel filer assembly (5) .

  1. Remove bolts (13) from bracket (14). Remove bracket (14) .

Installation Procedure




    Illustration 4g03646163

    Typical example

  1. Remove the plug from the fuel connection. Install the new 439-8115 Fuel Line (1) to fuel connection (2). Orientate the tube assembly such that the fourth leg at Position (X) is vertical. Refer to illustration 4. Tighten the tube nut finger tight.



    Illustration 5g03646171

    Typical example

  1. Position bracket (4) onto the cover of the inlet manifold.

  1. Install 6I-0260 Bolts (3) to the bracket (4). Tighten the bolts to a torque of 22 N·m (195 lb in).



    Illustration 6g03645420

    Typical example

  1. Position the bracket (5) onto bracket (4) .

  1. Install nuts (6). Tighten the nuts to a torque of 44 N·m (32 lb ft).

  1. Install bolt (7) finger tight.



    Illustration 7g03646753

    Typical example

  1. Position secondary fuel filter base (9) onto bracket (5) (not shown). Ensure that the end of 439-8115 Fuel Line (1) correctly installed into secondary fuel filter base (9). Tighten the tube nut for 439-8115 Fuel Line (1) finger tight.

  1. Install two bolts (8) to secondary fuel filter base (9) finger tight.

  1. If necessary, use slotted holes in the secondary fuel filter base (9) to achieve optimum position. Tighten bolts (8) to a torque of 44 N·m (32 lb ft).

  1. Ensure that 439-8115 Fuel Line (1) is still in the correct position. Tighten the compression nuts on 439-8115 Fuel Line to a torque of 27 N·m (239 lb in).

  1. Tighten bolt (6) (not shown) for clip to a torque of 22 N·m (195 lb in). Refer to Illustration 6.

  1. Remove cap from connection for plastic tube assembly (10) on secondary fuel filter base (9). Remove plug from plastic tube assembly (10). Connect the plastic tube assembly to the secondary fuel filter base.

  1. Remove cap from connection for plastic tube assembly (11) on secondary fuel filter base (9). Remove plug from plastic tube assembly (11). Connect the plastic tube assembly to the secondary fuel filter base.

  1. Install plastic tube assembly (11) to clip (12) .

  1. Install bolt (13) to clip for plastic tube assembly (11). Tighten the bolts to a torque of 44 N·m (32 lb ft). Ensure that the clip and the plastic tube assembly are not stained as the bolt is tightened.

  1. Position clips (15) onto tube assembly (14). Ensure that the clips are correctly positioned and orientated onto the tube assembly.

  1. If necessary, install a new fuel injection line to the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.

  1. Tighten the bolts (16) to a torque of 22 N·m (195 lb in). Ensure that the clips are not strained as the bolts are tightened.

  1. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.

  1. Start the engine. Refer to Operation and Maintenance Manual for the correct procedure. Check the fuel system for leaks.

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