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

Integrated Toolcarrier:

IT38H (S/N: JNJ1-400,500-529)

Wheel Loader:

938H (S/N: MCC1-273; MJC1-1064; JKM1-1096; LKM1-652,1000-1148)

Introduction

There have been isolated instances of issues with 353-3571 Filter Tube that are installed on certain 938H Machines with a C6.6 engine.

The fuel system can have four different types of tube assemblies installed between the secondary fuel filter assembly and the fuel injection pump. Previous Special Instruction, REHS3755, "New Tube Assembly for the Low-Pressure Fuel System on Certain C6.6 Machine Engines" for further information.

Inspect the machine in order to determine the configuration of the low-pressure fuel system. Refer to Illustration 1 and Illustration 5 in order to determine the configuration of the low-pressure fuel system.

Refer to ""Removal Procedure for Type One Low Pressure Fuel System" " for the required parts for a type one low-pressure fuel system.

Refer to ""Removal Procedure for Type Two Low Pressure Fuel System" " for the required parts for a type two low-pressure fuel system.

Removal Procedure for Type One Low Pressure Fuel System

Required Parts

For the O-ring seal, flat face connections type tube assembly. A full replacement of all the fuel system components should be carried out.

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Illustration 1	g03645462
O-ring seal, flat face connections type tube assembly

1. Turn the fuel supply to the OFF position.

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

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Illustration 2	g03645634
Typical example

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Illustration 3	g03645653

3. Disconnect tube assembly (5). Use Tooling (A) to cap the connection on the secondary fuel filer assembly. Use Tooling (A) to cap the tube assembly.

4. Disconnect plastic tube assembly (4). Use Tooling (A) to cap the connection on the secondary fuel filer assembly. Use Tooling (A) to plug the plastic tube assembly.

5. Disconnect plastic tube assembly (6). Use Tooling (A) to cap the connection on the fuel filer. Use Tooling (A) to plug the plastic tube assembly.

6. Remove bolt (8) the bracket. Remove the plastic tube assembly from clip (7) .

7. Remove existing secondary fuel filter base (3). Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install (Secondary Fuel Filter)" for the correct procedure.

8. Discard the secondary fuel filter base. Retain the two 6I-0593 Bolts .

9. Remove bracket (2) 311-1737 Bracket As . Retain the bracket and the nuts.

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Illustration 4	g03645417
Typical example

10. Remove crankcase breather canister (15). Refer to Operation and Maintenance Manual, "Crankcase Breather (Canister) - Replace" for the correct procedure.

11. Remove bolts (14). Remove fuel injection line (12). Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.

12. Remove and retain the fuel injection line mounting clips (13) .

13. Remove bolts (9) and remove bracket (10). Retain the three 6I-0260 Bolts .

14. Disconnect tube assembly (4) from the fuel injection pump. Remove connection (11) from the fuel injection pump. Use Tooling (A) to plug the fuel injection pump.

Removal Procedure for Type Two Low Pressure Fuel System

For the tube assembly with plastic section incorporated between the two steel sections. Replacement of tube assembly only for fuel system should be carried out.

Required Parts

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Illustration 5	g03646083
Tube assembly with plastic section incorporated between the two steel sections

1. Turn the fuel supply to the OFF position.

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

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Illustration 6	g03646084
Typical example

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Illustration 7	g03645418
Typical example

3. Remove bolt (1) from the clip for tube assembly (4) .

4. Remove nut (2) from the clip for tube assembly (4) .

5. Remove tube assembly (4) from fuel injection pump (6) and secondary fuel filer assembly (3) .

6. Use Tooling (A) to cap the connection on secondary fuel filer assembly (3). Use Tooling (A) to cap the connection on fuel injection pump (6) .

7. Loosen bolts (5) for secondary fuel filer assembly (3) .

Installation Procedure for the New tube Assembly Only for the Low-Pressure Fuel System

Replacement of the new tube assembly only to the low-pressure fuel system.

Required Part

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Illustration 8	g03646084
Typical example

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Illustration 9	g03645418
Typical example

1. Remove caps from the connection on secondary fuel filer assembly (3) and from the connection on fuel injection pump (6) .

2. Install the new 439-8115 Fuel Line (1) to secondary fuel filer assembly (3) and to the connection on fuel injection pump (6). Hand tighten the tube nuts for the tube assembly. Ensure that the tube assembly is correctly seated into the connection of the secondary fuel filer assembly and the fuel injection pump.

   Note: No clip is installed to the new tube assembly so nut (2) will not be required.

3. Install bolt (1) to the clip for tube assembly (4) hand tight.

4. Finger tighten bolts (5) for secondary fuel filer assembly (3) .

5. If necessary, use slotted holes in the secondary fuel filter base (3) to achieve optimum position. Tighten bolts (5) to a torque of 44 N·m (32 lb ft).

6. Tighten the compression nuts on 439-8115 Fuel Line to a torque of 27 N·m (239 lb in).

7. Tighten bolt (1) for clip to a torque of 22 N·m (195 lb in). Refer to Illustration 12.

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

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

Installation Procedure of the Latest Low Pressure Fuel System

Replacement of all the components must be carried out, in order to expedite a full repair to the low-pressure fuel system.

Required Parts

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Illustration 10	g03646163
Typical example

1. Remove the plug from the fuel injection pump. Install 356-4028 Fuel Connection (2) into the fuel injection pump. Tighten the fuel connection (2) to a torque of 30 N·m (22 lb ft).

2. Install the new 439-8115 Fuel Line (1) to the fuel connection. Orientate the tube assembly such that the fourth leg at Position (X) is vertical. Refer to illustration 10. Tighten the nut finger tight.

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Illustration 11	g03646171
Typical example

3. Position 354-5556 Bracket As (4) onto the cover of the inlet manifold.

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

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Illustration 12	g03645420
Typical example

5. Position the 311-1737 Bracket As (5) onto bracket (4) .

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

7. Install 100-4458 Bolt (7) finger tight.

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Illustration 13	g03646753
Typical example

8. Position 353-3588 Filter (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.

9. Install two 6I-0593 Bolts (8) to 353-3588 Filter finger tight.

10. 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).

11. 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).

12. Tighten bolt (6) (not shown) for clip to a torque of 22 N·m (195 lb in). Refer to Illustration 12.

13. 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.

14. 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.

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

16. 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.

17. Position clips (15) onto 355-1582 Tube As (14). Ensure that the clips are correctly positioned and orientated onto the tube assembly.

18. Install the new tube assembly to the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.

19. 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.

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

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