Inspection, Salvage, Reuse, Cleaning of the C175 Engine Fuel Rails & Critical Fuel Lines {0680, 0706, 0782, 1251, 1252, 127A} Caterpillar

Caterpillar Products

All C175 Engines

Introduction

Table 1

Revision	Summary of Changes in M0072382
08	Added new serial number prefixes for New Product Introduction (NPI).
07	Corrected Portable Diesel Fuel System Filtration Unit part number from 295-5970 to 295-5490.
06	Added SEBF9107, SEBF9109, and SEBF9112 as well as added instructions to properly clean HP fuel lines and to perform audit procedure.

© 2019 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. 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. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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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.

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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

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Ensure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.

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 which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

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 safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. 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, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

This document is intended to assist the dealer to disassembly, assembly, inspection, salvage, and cleaning of the fuel rail for the C175 engines. While cleaning the fuel rails, the clean side of the fuel system is exposed to atmosphere. Technicians should take great care to control contamination of the fuel system.

Maintaining cleanliness is also important to the health of high-pressure joints in the system. Proper handling and cleaning will ensure that critical sealing faces are not damaged. Use the tools that are outlined in this guideline to clean each of the critical sealing faces. The faces must be cleaned after any exposure to open air during assembly or removal from the fuel system. This cleanliness requirement also applies to new parts.

Contaminates that can damage the fuel system may require magnification to be seen. There is a broad range of debris that may cause unwanted damage to the system. Because the quality of the environment (air, dirty tools, dirty shop towels, and so forth) cannot be controlled in all cases. Therefore, it is difficult to determine the extent of damage that can potentially be caused in each case. All debris is considered harmful. By demonstrating the best practices during handling, the potential for premature failures can be minimized.

Service Letters and Technical Information Bulletins

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NOTICE
The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

References

Table 2

References
Media Number	Title
M0073882	Tool Operating Manual, " 502-0889 C175 Common Rail Assembly and Flushing Group"
MG1058	Manufacturing Practice, "Diesel Fuel Cleanliness Analysis By Automatic Particle Counting"
NEHS0799	Tool Operating Manual, " 170-8500 Analyzer Group"
NEHS0969	Tool Operating Manual, " 292-8713 Diesel Fuel System Filter Cart"
NEHS0989	Tool Operating Manual, " 295-5490 Portable Diesel Fuel System Filtration Unit"
PEBJ0002	Contamination Control Guideline, "Cat dealer Contamination Control Guidelines"
PEBJ9180	Contamination Control Guideline, "Cat dealer Contamination Control Guidelines"
RENR7466	Disassembly and Assembly, " 170-8500 Analyzer Group"
SEBF9180	Tool Operating Manual, "C175 Engine"

Tooling and Equipment

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NOTICE
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

Table 3

Required Tooling and Equipment
Part Number	Description
1P-1863	Retaining Ring Pliers
1P-5572	3/4" Cylinder Brush
1S-0258	Soft Face Hammer
3E-6790	O-Ring Seal
4C-6974	Pipe Wrench
4C-8515	Flap Wheel
4C-8520	Mandrel
6I-6851	Connector
6V-3965	Nipple
6V-4144	Coupler
6V-4365	O-Ring Seal
6V-9873	Adapter
8C-3076	O-Ring Seal
8S-2257	Eye Loupe
8T-3613	Nipple
8T-0222	Adapter
9A-1593	Metal Marking Pen
9U-7071	Tapered Cap/Plug
9U-7072	Tapered Cap/Plug
9U-7080	Tapered Cap/Plug
9U-7084	Tapered Cap/Plug
9U-7085	Tapered Cap/Plug
9U-7087	Tapered Cap/Plug
9U-7088	Tapered Cap/Plug
114-3399	Nipple
170-8500	Particle Analyzer
214-7347	Multiple Position Pliers
223-1154	Air Engraver
223-1694	Dead Blow Hammer
233-1642	Socket Set
239-4142	Handled Pry Bar
246-5181	Large Disposable Latex Gloves
249-5285	Stem Mount Wire Brush
260-1779	X-Large Disposable Latex Gloves
262-4868	Cleaning Brush
268-1582	Nipple
268-1583	Coupler
270-5342	Clear Contamination Control Bags
276-7018	Plug Cap Kit
292-8713	Diesel Fuel System Filter Cart
295-5490	Portable Diesel Fuel System Filtration Unit
303-9339	Lint Free Shop Towels
311-8193	M10 X 1.5 Bolt
330-3517	O-Ring Seal
330-7185	Connector Assembly
334-4442	Connector Assembly
339-9352	Service Cap Kit for Injectors, High-Pressure Fuel Lines, and Flow Limiter
339-9353	Service Cap Kit for High-Pressure Fuel Pump
339-9354	Service Cap Kit for Common Rail
382-5051	Fuel Injection Pump Kit
383-4255	Monitor Assembly (Contamination Control)
386-3239	T-Handle Allen Head Wrench Set
489-7662	Rail Fixture
502-0889	Fuel Rail Flushing Tool
514-4580	Alignment Bar
514-4581	Adapter
514-4582	End Plug Adapter
-	"LPS CFC Free Electro Contact Cleaner"(1)

(1)	The LPS cleaner is the cleaner that is preferred. The LPS cleaner can be purchased in an aerosol or bulk. If LPS is not available, 99.9% isopropyl alcohol can be used.

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

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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.

Criteria on Components

The following items can damage the high pressure sealing surfaces:

• Improper Handling

• Improper Storage

• Improper Disassembly and Assembly Procedures

The components of the common rail fuel system require special guidelines for handling to ensure optimum performance. The fuel system contains many spherical ball and conical joints, which perform high-pressure sealing.

The system is designed to operate at a nominal fuel pressure of 1880 bar (27260 psi). Handle the components carefully when you disassemble the fuel system. The high-pressure fuel system is composed of the following components:

• High-Pressure Fuel Pump

• High-Pressure Lines, High-Pressure Rails, and Flow Limiters

• Fuel Injectors

The higher system pressures demand more stringent standards for cleanliness. The fuel that is within the fuel tank must meet ISO 18/16/13 specifications. The fuel that is in the common rail fuel system post primary and secondary fuel filtration must meet ISO 15/13/10 specifications.

Clean each of the sealing surfaces even if the parts are new. Fuel system components are sensitive to debris and great care should be taken when cleaning fuel system sealing surfaces. Use only "LPS CFC Free Electro Contact Cleaner" or 99.9% Isopropyl Alcohol to rinse the parts. Use clean, dry compressed air to dry the parts.

Backflushing Fuel System

This procedure will provide information that will assist the technician in filtering the common rail fuel system. Contamination of the fuel system, or failed components in the fuel system will require the system to be flushed. Any debris in the fuel system can cause damage to the injectors or the flow limiters. Filter the system using the 292-8713 Diesel Fuel System Filter Cart or 295-5490 Portable Diesel Fuel System Filtration Unit, 330-7185 Connector Assembly, and 334-4442 Connector Assembly must occur before the engine is operated or disassembly of fuel components. Filtering the fuel system will allow some of the fuel system components to be used again.

Illustration 3	g06251572
Connector Assemblies for flushing the fuel system (6) 330-7185 Connector Assembly (7) 334-4442 Connector Assembly

Contamination Control

Each of the fittings on the filter cart contains a dust cap. Each of the dust caps should only be removed at the time of use. Reinstall the dust caps immediately after use.

The high-pressure fuel line of the common rail fuel system will not need to be disassembled. It will be necessary to remove the high-pressure fuel line on the number two cylinder. Install protective caps on any component that is removed from the fuel system to prevent contamination of the fuel system. Clean the components of the fuel system with isopropyl alcohol. Do not allow any of the components to touch any item before assembly.

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Use caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol. Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol. Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding 482°C (900°F).

Purging System Pressure

Purge the fuel system pressure before doing any work on the engine. The fuel system contains high-pressure fuel and exposure to high-pressure fuel can result in personal injury. Allowing the engine to sit for 15 minutes after being operated will allow the fuel system to return to a safe pressure level. Use Electronic Technician to verify that fuel system pressure and temperature have returned to a safe level before opening the system.

Preparation of the Portable Filter Cart

A good understanding of the operation of the filter cart will be necessary to flush the fuel system. Review Tool Operating Manual, NEHS0969, " 292-8713 Diesel Fuel System Filter Cart" or Tool Operating Manual, NEHS0989, " 295-5490 Portable Diesel Fuel System Filtration Unit" for complete instructions on the filter cart, analyze the fuel system for contamination.

1. Verify that the quick disconnect fittings for air lines are installed on the filter cart.

2. Fill the fuel tank of the filter cart with clean diesel fuel.

3. Connect a regulated air line to the filter cart. A minimum of 138 kPa (20.0 psi) will be necessary to operate the filter cart. Pressure up to 276 kPa (40.0 psi) may be used.
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   Illustration 4	g06251576
   Ground strap

4. Secure the ground strap of the filter cart to a known good ground on the machinery.
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   Illustration 5	g06251580
   Example of 170-8500 Particle Analyzer connected to filter cart.

5. Use 170-8500 Particle Analyzer or 383-4255 Monitor Assembly to check the cleanliness of the fuel. Connect the analyzer to the filter cart.
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   Illustration 6	g06251581
   Example of connected lines of the filter cart

6. Connect the fuel supply connector and the fuel return connector together and operate the filter cart until ISO 15/13/10 specification is met. Refer to Tool Operating Manual, NEHS0799, " 170-8500 Particle Analyzer" for complete operating instructions for the particle analyzer.

   Refer to Manufacturing Practice, MG1058, "Diesel Fuel Cleanliness Analysis By Automatic Particle Counting" for instruction on counting particles in diesel fuel.

   Note: If a particle analyzer is not available, flush the fuel in the cart for 40 minutes.

Preparation of the Engine

Illustration 7	g06251582
(6) 330-7185 Connector Assembly (7) 334-4442 Connector Assembly (8) High-pressure fuel line (9) High-pressure pump line (10) Junction block

Note: Purge the fuel system pressure before doing any work on the engine. The fuel system contains high-pressure fuel and exposure to high-pressure fuel can result in personal injury. Allowing the engine to sit for 15 minutes after being operated will allow the fuel system to return to a safe pressure level. Use Electronic Technician to verify that fuel system pressure and temperature have returned to a safe level before opening the system.

Note: Any components that have been removed must be sealed to prevent contamination. Plug any orifices that are exposed after parts have been removed.

1. Clean the area around the high-pressure fuel line on the number two cylinder. Be sure that no dirt or debris can enter the fuel system. Fuel system components can easily be damaged by dirt and debris.
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   Illustration 8	g06251584
   Removal of the high-pressure fuel line and bypass line

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   Illustration 9	g06251587
   Sealed orifices of the fuel system (11) 9U-7085 Plug (12) 9U-7087 Plug (13) 9U-7072 Plug

2. Remove the bypass line and remove the high-pressure fuel line on the number two cylinder. Refer to Disassembly and Assembly, RENR7466, for information and the disassembly and assembly of the fuel system. Install plugs and caps on any exposed orifice of the fuel system to prevent dirt and debris from entering. Refer to Section "Contamination Control Information" for information on the plugs and caps that are used to cover the exposed orifices of the fuel system.
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   Illustration 10	g06251589
   Installation of 330-7185 Connector Assembly

3. Install the 330-7185 Connector Assembly in place of the high-pressure fuel line on the number two cylinder. Thoroughly clean the adapter of the fuel supply before installation.
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   Illustration 11	g06251590
   (14) 9U-7085 Plug

4. Remove the high-pressure pump line between the fuel pump and the junction block of the fuel rail. Install 9U-7085 Plug in the outlet of the high-pressure fuel pump.
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   Illustration 12	g06251594
   Installation of 334-4442 Connector Assembly

5. Install 334-4442 Connector Assembly onto the junction block in place of the high-pressure pump line. Thoroughly clean the connector assembly before installation.

6. Leave all other fuel system components intact. Removal of more fuel system components is not necessary.

Procedure for Filtering the Fuel System

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Illustration 13	g06251592
Fuel supply line

1. Connect 330-7185 Connector Assembly to the connector of the fuel supply line on the filter cart.
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   Illustration 14	g06251594
   Adapter for fuel return

2. Connect 334-4442 Connector Assembly to the connector of the fuel return line on the filter cart.

3. Operate the filter cart and allow the filter cart to run for 60 minutes.
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   Illustration 15	g06251596
   Example of 170-8500 Particle Analyzer.

4. Monitor the particle analyzer and flush the system until ISO 15/13/10 is met.

5. Disconnect the filter cart and the flushing connectors from the engine. Prepare the filter cart for storage.

6. Reassemble the fuel system after verifying that flush results are acceptable.

7. Start and run the engine for one to two hours.

8. Perform all tests of the fuel system to verify that the system is operating properly.

9. Return the unit back to service if results of the tests are acceptable.

10. Failed tests will require the troubleshooting of the cause of the failed results.

Right Side Fuel Rail Disassembly and Cleaning

Right Side Fuel Rail Disassembly

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Illustration 16	g06080181

1. Install the fuel rail on the 489-7662 Rail Fixture.
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   Illustration 17	g06080184

2. Secure the fuel rail on the adapter with bolts as shown.
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   Illustration 18	g06080193

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   Illustration 19	g06080202

3. Scribe corresponding identification marks on all adapters and quill tubes to identify locations for reassembly.
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   Illustration 20	g06080766

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   Illustration 21	g06080777

4. Remove the quill tubes. Carefully pry on the outer flange to remove the quill tube. Perform a quick visual inspection on each end of the quill tube. Look for scratches across the sealing bands. If the sealing bands are damaged, the parts cannot be reused. Set all parts aside for cleaning.
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   Illustration 22	g06080793

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   Illustration 23	g06080788

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   Illustration 24	g06080799

5. Scribe corresponding identification marks on all flow limiters. Remove flow limiters from the rail supports. A band of debris may prevent the flow limiter from coming out without using a gripping tool. Grip only on the flats of the flow limiter. Perform a quick visual inspection on each flow limiter. Look for scratches across the sealing bands. Set all parts aside for cleaning.
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   Illustration 25	g06080818

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   Illustration 26	g06080825

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   Illustration 27	g06080829

6. Unscrew the flange from the right side of the rail. Move to the opposite end of the rail and unscrew the flange. The tube may come off with the flange and this is acceptable. The tube will be removed from the flange later before the cleaning steps. Remove the o-ring and perform a quick visual inspection.
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   Illustration 28	g06080840

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   Illustration 29	g06080842

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   Illustration 30	g06080846

7. Mark the flanges, tubes, and the end of the rail so all the parts can be reassembled in the same orientation.

   Note: Do not attempt to remove the threaded end from the fuel rail. Removal will damage the fuel rail.

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   Illustration 31	g06080857

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   Illustration 32	g06080858

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   Illustration 33	g06080864

8. Lightly tap the rail with a soft mallet to get the rail loose. Remove the rail from the rail supports and the tube by twisting and pulling the opposite end. Wipe off loose debris with a clean lint free towel. Prepare the rail for washing and flushing by placing the rail on the supplied nylon vee blocks in the 502-0889 Fuel Rail Flushing Tool.
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   Illustration 34	g06080892

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   Illustration 35	g06080898

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   Illustration 36	g06080917

9. Begin to disassemble the tube and rail supports. Loosen one rail support at a time and separate the rail from the low-pressure leakage tubes. Remove the drain plug and o-ring from the rail support.
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   Illustration 37	g06080945

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   Illustration 38	g06080954

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   Illustration 39	g06080966

10. Remove the return line fittings from the rail adapter by removing the retaining bolt. Inspect the seal ring surfaces for damage.
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    Illustration 40	g06080973

11. Remove the injector return tube. The return tube may be difficult to remove from the adapter and may require a gripping tool and a tap from a soft mallet.
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    Illustration 41	g06080986

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    Illustration 42	g06080995

12. Remove the end tube from the flange that was removed earlier. Turn and lift simultaneously. Once the end tube is removed, the o-rings can be removed. Inspect the sealing surfaces.
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    Illustration 43	g06081013

13. Clean the sealing surfaces of the leakage tubes and return tubes with a wire brush before placing all these components in the cabinet washer.
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    Illustration 44	g06081029

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    Illustration 45	g06081076

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    Illustration 46	g06083408

14. Clean the bores of the adapters with various brushes, wheels, and techniques.
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    Illustration 47	g06083415

15. Clean all o-ring surfaces with a wire wheel.
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    Illustration 48	g06083429

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    Illustration 49	g06083438

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    Illustration 50	g06083461

16. Clean the quill tube o-ring grooves with a wire brush while rinsing with the parts washer.
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    Illustration 51	g06083479

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    Illustration 52	g06083484

17. Place the flow limiters in the ultrasonic bath for a minimum of 30 minutes. The temperature of the fluid should be 50° C (122° F).

18. Place all the larger components in the cabinet washer. Smaller parts should be washed in the parts washer by hand. Blow dry all parts with clean, dry compressed air. Place the clean components in a clean work area for reassembly.

Right Side Fuel Rail Assembly

Illustration 53	g06083551

Note: All seals used in the assembly of the fuel rails should be lightly coated with clean DEO at assembly.

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Illustration 54	g06083616

1. Starting at the left side of the fixture attach the first support to the assembly fixture using the supplied bolt.
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   Illustration 55	g06083554

2. Install 8C-3076 O-Ring Seal onto the plug. Install the plug into the rail support.
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   Illustration 56	g06083560

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   Illustration 57	g06083562

3. Install 330-3517 O-Ring Seal on the inner grove of the flange. Install 3E-6790 O-Ring Seal on the outer groove of the flange.
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   Illustration 58	g06083570

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   Illustration 59	g06083574

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   Illustration 60	g06083578

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   Illustration 61	g06083580

4. Lubricate the inner bore of the tube and press the flange into the bore of the tube. Seat the flange with a light tap from a soft mallet. Install the 3E-6790 O-Ring Seal onto the outer seal groove. Place the assembly to the side for later assembly to the rail.
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   Illustration 62	g06083584

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   Illustration 63	g06083590

5. Install the 6V-4365 O-Ring Seal onto the fuel connector. Install the fuel connector onto the outer port on the rail support. Install the bolt into the connector and torque to 12 ± 3 N·m (9 ± 2.2 lb ft).
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   Illustration 64	g06083615

6. Install one 6V-4365 O-Ring Seal on each end of the return tubes.
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   Illustration 65	g06083890

7. Install one 3E-6790 O-Ring Seal on each end of the leakage tubes.
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   Illustration 66	g06083920

8. Install the return tube into the rail support by lightly pressing and twisting the return tube. The joints will be loose but the return tube should bottom out in the respective ports. If the tube does not bottom out, remove the tube and inspect the bores and tubes for abnormal features, deformations, or obstructions. Replace the return tube or rail support if necessary.
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   Illustration 67	g06083922

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   Illustration 68	g06083935
   Example of leakage and return tubes installed onto the rail support.

9. Install the leakage tube into the rail support by lightly pressing and twisting the leakage tube. The joints will be loose but the leakage tube should bottom out in the respective ports. If the tube does not bottom out, remove the tube and inspect the bores and tubes for abnormal features, deformations, or obstructions. Replace the leakage tube or rail support if necessary.
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   Illustration 69	g06083979

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   Illustration 70	g06083985

10. Lubricate the ports and sealing surfaces with DEO. Install the next rail support by aligning the tubes on the previous assembly with the bores of the next rail support and pressing firmly on the rail support. Lightly tap the rail support onto the tubes with a soft mallet.
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    Illustration 71	g06083998

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    Illustration 72	g06084004

11. Once the tubes are seated into the rail support, the rail support will line up with the bolt holes on the fixture. Install the bolt and lightly snug the bolt. Repeat the tube and support installation process on the remaining stations.
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    Illustration 73	g06084081

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    Illustration 74	g06084087

12. After the rail has been thoroughly flushed and cleaned, place the rail and vee blocks on the assembly table. Be careful to keep the sealing surfaces upright and protected. With a clean lint free towel, wipe the entire outer rail surface down with clean DEO. Wiping the rail down with DEO will make installation much easier.
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    Illustration 75	g06084103

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    Illustration 76	g06084107

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    Illustration 77	g06084176

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    Illustration 78	g06084182

13. Carefully align the rail in the first rail support from the right-hand side. Gently guide the rail into the first few rail supports. As the rail is installed, loosen the bolts retaining the rail supports on the fixture allowing the rail to be installed freely.
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    Illustration 79	g06084192

14. Install the rail until there are equal amounts of the ends protrude on each end, about 50.0 mm (1.969 inch)
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    Illustration 80	g06084246

15. Roughly align the rail so that the flow limiter holes on the rail are centered in the bore of the rail support.
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    Illustration 81	g06085304

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    Illustration 82	g06085307

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    Illustration 83	g06085311

16. Use the 514-4580 Alignment Bar to align the fuel rail with the fuel rail supports. To align the rail with the rail supports, slowly engage the alignment bar into two consecutive stations. It will be necessary to loosen the bolts holding the rail supports to the fixture. As the rail aligns with the rail supports, the Alignment Bar will slowly engage into the bores eventually bottoming out. Once the alignment bar has bottomed out, tighten the bolts on the fixture. Remove the Alignment Bar and proceed to the next station until all the stations are complete. Do not loosen the bolts on those stations that have been aligned. Do not loosen the stations until the quill tubes are installed. This will ensure proper alignment with the quill tubes, flow limiters, and rail.
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    Illustration 84	g06084264

17. Install the limiter assembly into the rail support. Install the limiters in the same station it was removed from.
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    Illustration 85	g06084269

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    Illustration 86	g06084271

18. Lightly lubricate the 514-4581 Adapter o-rings with DEO. Install the flushing caps into the bores of the rail supports on top of the flow limiters. Press the flushing cap down until it bottoms out on the flow limiter. Torque the bolts evenly to 10 N·m (89 lb inch).
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    Illustration 87	g06084506

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    Illustration 88	g06084513

19. Install the tube and the flange that was assembled earlier. Lubricate the seals with clean DEO. Press the flange into the bore. Once the flange is seated on the rail, thread the connector onto the rail.
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    Illustration 89	g06084554

20. Install the support onto the rail support by pressing it onto the rail and into the bore of the rail support.
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    Illustration 90	g06084558

21. Install the flange onto the support by threading it onto the rail connector.
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    Illustration 91	g06084572

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    Illustration 92	g06084576

22. Install the two 514-4582 End Plug Adapter on the end flanges of the rail. Push the adapters into the bores until the adapters bottom out. Evenly torque both bolts to 10 N·m (89 lb in).
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    Illustration 93	g06084579

23. Install a cap on the fuel connector.
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    Illustration 94	g06084584

24. Install the flow tee in the connection. The rail is now ready to be flushed and low pressure tested. Remove the rail fixture from the assembly table and transfer it to the 502-0889 Fuel Rail Flushing Tool.

Left Side Fuel Rail Disassembly and Cleaning

Note: The disassembly and assembly of the left side fuel rail is similar to the right side. There are a few differences that should be noted.One end of the unit has a plug and retaining ring The retaining ring must be removed before the rail can be extracted.The left side fuel rail has a support and an adapter that must stay on the rail.The pressure sensor should be removed prior to disassembly and cleaning. Replace the pressure sensor prior to installing the fuel rail assembly to the engine.

Left Side Fuel Rail Disassembly

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Illustration 95	g06084558

1. Remove the flange from the right end of the rail as it was performed with the fuel rail by unthreading from the rail connector.
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   Illustration 96	g06084686

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   Illustration 97	g06084690

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   Illustration 98	g06084692

2. Remove the retaining ring from the opposite end of the rail using 1P-1863 Retaining Ring Pliers. Remove the tube from the rail support.

   Note: Do not remove the screw from the end of the rail. This screw has a crush fit seal that cannot be reused and it is not serviced currently.

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   Illustration 99	g06084700

3. Remove the rail support, leakage tube, and the return tube.
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   Illustration 100	g06084717

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   Illustration 101	g06084722

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   Illustration 102	g06084730

4. Begin to remove the fuel rail along with the attached flange. The flange must stay on the rail during disassembly, cleaning, flushing, and assembly. Do not remove the pressure sensor port from the flange as it has a crush seal and cannot be serviced. Clearance of the rail will be tight when pulling the rail past the rotating mechanism of the fixture.

   Note: Removal of the flange on the rail will damage the rail and sealing surfaces. Do not attempt to remove the flange. Do not remove the pressure sensor port from the flange as it will damage the flange.

5. Remove the leakage tubes, return tubes, and rail supports from the fixture as was done with the right side fuel rail. Clean all the parts as the right side fuel rail was cleaned.

Left Side Fuel Rail Assembly

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Illustration 103	g06083616

1. Starting at the left side of the fixture attach the first support to the assembly fixture using the supplied bolt.
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   Illustration 104	g06083554

2. Install 8C-3076 O-Ring Seal onto the plug. Install the plug into the rail support.
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   Illustration 105	g06083560

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   Illustration 106	g06083562

3. Install 330-3517 O-Ring Seal on the inner grove of the flange. Install 3E-6790 O-Ring Seal on the outer groove of the flange.
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   Illustration 107	g06083570

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   Illustration 108	g06083574

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   Illustration 109	g06083578

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   Illustration 110	g06083580

4. Lubricate the inner bore of the tube and press the flange into the bore of the tube. Lightly tap the tube with a soft mallet to seat the flange. Install the 3E-6790 O-Ring Seal onto the outer seal groove. Place the assembly to the side for later assembly to the rail.
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   Illustration 111	g06083584

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   Illustration 112	g06083590

5. Install the 6V-4365 O-Ring Seal onto the fuel connector. Install the fuel connector onto the outer port on the rail support. Install the bolt into the connector and torque to 12 ± 3 N·m (9 ± 2.2 lb ft).
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   Illustration 113	g06083615

6. Install one 6V-4365 O-Ring Seal on each end of the return tubes.
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   Illustration 114	g06083890

7. Install one 3E-6790 O-Ring Seal on each end of the leakage tubes.
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   Illustration 115	g06083920

8. Install the return tube into the rail support by lightly pressing and twisting the return tube. The joints will be loose but the return tube should bottom out in the respective ports. If the tube does not bottom out, remove the tube and inspect the bores and tubes for abnormal features, deformations, or obstructions. Replace the return tube or rail support if necessary.
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   Illustration 116	g06083922

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   Illustration 117	g06083935
   Example of leakage and return tubes installed onto the rail support.

9. Install the leakage tube into the rail support by lightly pressing and twisting the leakage tube. The joints will be loose but the leakage tube should bottom out in the respective ports. If the tube does not bottom out, remove the tube and inspect the bores and tubes for abnormal features, deformations, or obstructions. Replace the leakage tube or rail support if necessary.
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   Illustration 118	g06083979

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   Illustration 119	g06083985

10. Lubricate the ports and sealing surfaces with DEO. Install the next rail support by aligning the tubes on the previous assembly with the bores of the next rail support and pressing firmly on the rail support. Lightly tap the rail support onto the tubes with a soft mallet.
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    Illustration 120	g06083998

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    Illustration 121	g06084004

11. Once the tubes are seated into the rail support, the rail support will line up with the bolt holes on the fixture. Install the bolt and lightly snug the bolt. Repeat the tube and support installation process on the remaining stations.
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    Illustration 122	g06084081

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    Illustration 123	g06084087

12. After the rail has been thoroughly flushed and cleaned, place the rail and vee blocks on the assembly table. Be careful to keep the sealing surfaces upright and protected. With a clean lint free towel, wipe the entire outer rail surface down with clean DEO. Covering the rail with DEO will make installation much easier.
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    Illustration 124	g06084103

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    Illustration 125	g06084107

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    Illustration 126	g06084176

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    Illustration 127	g06084182

13. Carefully align the rail in the first rail support from the right-hand side. Gently guide the rail into the first few rail supports. As the rail is installed, loosen the bolts retaining the rail supports on the fixture allowing the rail to be installed freely.
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    Illustration 128	g06084192

14. Install the rail until there are equal amounts of the ends protrude on each end, about 50.0 mm (1.969 inch)
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    Illustration 129	g06084246

15. Roughly align the rail so that the flow limiter holes on the rail are centered in the bore of the rail support.
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    Illustration 130	g06085304

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    Illustration 131	g06085307

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    Illustration 132	g06085311

16. Use the 514-4580 Alignment Bar to align the fuel rail with the fuel rail supports. To align the rail with the rail supports, slowly engage the alignment bar into two consecutive stations while loosening the bolts holding the rail supports to the fixture. As the rail aligns with the rail supports, the Alignment Bar will slowly engage into the bores eventually bottoming out. Once the alignment bar has bottomed out, tighten the bolts on the fixture. Remove the Alignment Bar and proceed to the next station until all the stations are complete. Do not loosen the bolts on those stations that have been aligned. Do not loosen the stations until the quill tubes are installed. This will ensure proper alignment with the quill tubes, flow limiters, and rail.
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    Illustration 133	g06084264

17. Install the limiter assembly into the rail support. Install the limiters in the same station that it was removed from.
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    Illustration 134	g06084269

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    Illustration 135	g06084271

18. Lightly lubricate the 514-4581 Adapter o-rings with DEO. Install the flushing caps into the bores of the rail supports on top of the flow limiters. Press the flushing cap down until it bottoms out on the flow limiter. Torque the bolts evenly to 10 N·m (89 lb inch).
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    Illustration 136	g06084506

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    Illustration 137	g06084513

19. Install the tube and the flange that was assembled earlier. Lubricate the seals with clean DEO. Press the flange into the bore. Once the flange is seated on the rail, thread the connector onto the rail.
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    Illustration 138	g06084554

20. Install the support onto the rail support by pressing it onto the rail and into the bore of the rail support.
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    Illustration 139	g06084558

21. Install the flange onto the support by threading it onto the rail connector.
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    Illustration 140	g06084572

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    Illustration 141	g06084576

22. Install the 514-4582 End Plug Adapter on the open-end flange of the rail. Push plug into the bores until the plug bottom out. Evenly torque both bolts to 10 N·m (89 lb inch).
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    Illustration 142	g06084584

23. Install the flow tee in the connection. The rail is now ready to be flushed and low pressure tested. Remove the rail fixture from the assembly table and transfer it to the 502-0889 Fuel Rail Flushing Tool.

Flushing and Verifying Cleanliness of Supply and Return Tubes after Removal from Engine Using Filter Cart

Illustration 143	g06255229
(1) Supply Tube

Illustration 144	g06255232
(2) Supply Tube

Illustration 145	g06255236
(3) Cross Over Delivery Tube (4) Return Tube

Illustration 146	g06255227
(5) Fuel Filter Tube for 16 cylinder

Illustration 147	g06255331
(6) Fuel Filter Tube for 20 cylinder

Note: Ensure that the reservoir on the filter cart is filled with clean diesel fuel.

The return and supply tubes require flushing and verifying with 292-8713 Diesel Fuel System Filter Cart or 295-5490 Portable Diesel Fuel System Filtration Unit after initial cleaning. It is recommended that all the paints be removed from the tubes before flushing with filter cart to reduce the chance of paint chip contamination of the fluid.

Tooling and Fittings Required

Tube manifold assemblies must be made out of aluminum before starting this procedure and fittings/adapters will be needed as well. Refer to Illustration 148 through Illustration 152 and the dimensions in Table 4.

Illustration 148	g06251920
Tube Manifold Assembly

Table 4

Tube Manifold Assembly Dimensions (1)
Callout	Dimensions
A	45.0 ± 3.0 mm (1.77 ± 0.118 inch)
B	22.5 ± 0.1 mm (0.886 ± 0.004 inch)
C	11.0 ± 0.1 mm (0.433 ± 0.004 inch)
D	38.0 ± 0.1 mm (1.496 ± 0.004 inch)
E	65.0 ± 0.1 mm (2.559 ± 0.004 inch)
F	M10 TO A DEPTH OF 25.0 mm (0.984 inch) X 2
G	76.0 ± 3.0 mm (2.99 ± 0.118 inch)
H	Ø 40.8 ± 0.1 mm (1.606 ± 0.004 inch)
J	Ø 35.6 ± 0.1 mm (1.402 ± 0.004 inch)
K	Ø 27.0 ± 0.5 mm (1.063 ± 0.019 inch)
L	R3.0 ± 1.0 mm (0.118 ± 0.039 inch)
M	3.2 ± 0.1 mm (0.126 ± 0.004 inch)
N	8.0 ± 0.1 mm (0.315 ± 0.004 inch)
P	50.8 ± 0.1 mm (2.000 ± 0.004 inch)
R	C/R 3.0 mm (0.118 inch) MAX
S	1/8 NPT THD
T	36.0 ± 1.0 mm (1.417 ± 0.039 inch)
U	14.0 ± 0.1 mm (0.551 ± 0.004 inch)
V	3 X R1.0 ± 0.5 mm (0.039 ± 0.019 inch)

(1)	To be made from aluminum

Illustration 149	g06252173
Example of option 1 for Return Tube adapters. (W) 6V-9873 Adapter (X) 8W-0222 Adapter (Y) 6V-3965 Adapter

Illustration 150	g06252203
Example of option 2 for Return Tube adapter and connector. (Y) 6V-3965 Adapter (Z) 6I-6851 Connector

Illustration 151	g06252158
Example of filter cart adapter assemblies. (AA) 6V-4144 Coupler (AB) 114-3399 Pipe Nipple (AC) 268-1583 Nipple (AD) 268-1582 Coupler

Illustration 152	g06251950
Example of finished Tube Manifold. with O-Ring Seal and Nipple installed. (AE) 330-3517 O-Ring Seal (AF) 8T-3613 Nipple

Install a 330-3517 O-Ring Seal (W) and 8T-3613 Nipple (X) in the manifold as shown in Illustration 152.

Procedure for Cross Over Delivery Tube

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Illustration 153	g06252250

1. Install the Tube Manifolds on the ends of the tubes and secure with original bolts or 311-8193 Bolts.
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   Illustration 154	g06252248

2. Attach the fluid supply quick disconnect and a flushing manifold quick disconnect to the adapter blocks.
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   Illustration 155	g06252255

3. Allow the tube to be flushed in both directions for 1 to 2 minutes.
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   Illustration 156	g06251580
   Example of 170-8500 Particle Analyzer connected to filter cart.

4. Monitor 170-8500 Particle Analyzer or 383-4255 Monitor Assembly and flush the system until ISO 15/13/10 is met.

5. Remove one manifold and use clean dry air to blow the residual fluid back into the filter cart.

6. Remove the other manifold and prep for storage or installation. Refer to Section "Contamination Control Information" for information on the plugs used to cover the exposed orifices.

Procedure for Return Tube and Fuel Filter Tubes

There are 2 options of adapters/connectors for the flushing of the return tube and fuel filter lines.

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Illustration 157	g06252278
Example of option 1 for connecting return tube and fuel filter tube.

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Illustration 158	g06135567
Example of option 2 for connecting return tube and fuel filter tube.

1. Either install 6V-9873 Adapter (W), 8W-0222 Adapter (X), and 6V-3965 Adapter (Y) or 6I-6851 Connector (Z) and 6V-3965 Adapter (Y) into both ends of the tube.
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   Illustration 159	g06252283

2. Attach the fluid supply quick disconnect on the ends of the tube.
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   Illustration 160	g06252286

3. Allow the tube to be flushed in both directions for 1 to 2 minutes.
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   Illustration 161	g06251580
   Example of 170-8500 Particle Analyzer connected to filter cart.

4. Monitor 170-8500 Particle Analyzer or 383-4255 Monitor Assembly and flush the system until ISO 15/13/10 is met.

5. Remove the adapter on one side of the tube and use clean dry air to blow the residual fluid back into the filter cart.

6. Remove the adapter and prep for storage or installation. Refer to Section "Contamination Control Information" for information on the caps used to cover the exposed orifices.

Procedure for Supply Tubes

There are 2 options for flushing supply tubes, either individually or assembled. It would be best if the Edge Filter is removed from the Filter Housing so the housing itself can be cleaned and flushed. The Edge Filter should be replaced.

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Illustration 162	g06252319
Example of flushing the supply lines individually.

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Illustration 163	g06252324
Example of flushing the supply lines as an assembly after removing Edge Filter from Filter Housing. (AG) Filter Housing

1. Install the Tube Manifolds on the ends of the tubes and secure with original bolts or 311-8193 Bolts.

2. Attach the fluid supply quick disconnect on the ends of the tube manifolds.

3. Allow the tube to be flushed in both directions for 1 to 2 minutes.
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   Illustration 164	g06251580
   Example of 170-8500 Particle Analyzer connected to filter cart.

4. Monitor 170-8500 Particle Analyzer or 383-4255 Monitor Assembly and flush the system until ISO 15/13/10 is met.

5. Remove one manifold and use clean dry air to blow the residual fluid back into the filter cart.

6. Remove the other manifolds and prep for storage or installation. Refer to Section "Contamination Control Information" for information on the plugs used to cover the exposed orifices.

Sealing Band

Illustration 165	g01271647
Conical Sealing Surface of a Fuel Injector (1) Sealing band

Sealing band (1) is the point of contact between the spherical ball and the conical joint. This band can be seen on all the components that have been in service. Sealing band (1) can be seen on both the spherical ball and the conical joint.

Illustration 166	g01335686
(1) Sealing band (2) Scratches that are not on the sealing band (3) Scratches that are on the sealing band

If there are scratches that are on the sealing band, do not use the component again. The scratches may create a leak. Some scratches also create an area of raised material on either side of the scratch. The raised material may not allow the mating surfaces to seal properly.

If there are scratches that are not on the sealing band, the component may be able to be used again. Even though the scratches are not on the sealing band, inspect the scratches carefully. If there is any raised material on either side of the scratch, the raised material may not allow the mating surfaces to seal properly.

If there is raised material on either side of the scratch, do not attempt to remove the raised material. If the material that is removed falls into the component and the technician does not notice, many other components may be destroyed when the engine is operated again.

Avoiding Damage to the High Pressure Sealing Surfaces

Always follow the Disassembly and Assembly procedures. Damage can occur to the high pressure sealing surfaces by removing parts improperly. Refer to Disassembly and Assembly Manual for your machine.

Immediately upon disassembling the components, install a protective end cap to the high pressure sealing surfaces.

Illustration 167	g01303578
Damage to the High-Pressure Line Assembly Do Not Reuse

Illustration 168	g01303585
Damage to the High-Pressure Line Assembly Do Not Reuse

Visual Inspection of the High Pressure Sealing Surfaces

The sealing surfaces on the following components must be inspected and cleaned prior to installation:

• Fuel Injectors

• High-Pressure Lines

• Flow Limiters

• Fuel Pump

Hold the component near a light source to inspect the sealing band. Rotate the component for 360 degrees to inspect the sealing band.

Note: If the component has stains from fuel on the sealing surface, inspect the component carefully. Stains from fuel do not always mean that a leak is present, but the stains from fuel are present in the area of a leak.

Some of the damage may not be seen without magnification. The use of an 8S-2257 Eye Loupe may be necessary to inspect the high pressure sealing surfaces.

If the component can be reused, use the proper procedure to clean the components.

Fuel Injectors

Illustration 169	g01303710

The conical sealing surface on this fuel injector has circumferential scratches only.

OK To Reuse

Flow Limiters

Illustration 170	g01271650
Spherical Sealing Surface of a Flow Limiter

Illustration 171	g01303603

This high pressure sealing surface has a scratch that crosses the sealing band.

Do Not Reuse

Illustration 172	g01271649

The conical surface on this flow limiter has heavy scratches from abuse.

Do Not Reuse

Illustration 173	g01303623

This defect extends across the sealing band.

Do Not Reuse

High-Pressure Line Assembly

Illustration 174	g01271651

This high pressure sealing surface does not have any defects that will allow the fuel to cross the sealing band.

Ok To Reuse

High-Pressure Fuel Line

Illustration 175	g01271653

Defect does not extend across the sealing band.

Ok To Reuse

Illustration 176	g01303947

The defect extends across the sealing band.

Do Not Reuse

Illustration 177	g01303949

Although this scratch is small, the scratch extends across the sealing band.

Do Not Reuse

Illustration 178	g01303968

This defect extends into the sealing band from the pressure side of the sealing surface.

Do Not Reuse

Contamination Control Information

Lines, Tubes, and Hoses

Do not bend or strike high-pressure lines. Do not install lines, tubes, or hoses that are damaged.

Replace any fuel lines, oil lines, tubes, or hoses that are loose or damaged. Leaks can cause fires.

Inspect all lines, tubes, and hoses carefully. Do not use bare hands to check for leaks. Always use a board or cardboard for checking engine components for leaks. Tighten all connections to the recommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

Ensure that all the clamps, the guards, and the heat shields are installed correctly. This installation will help to prevent these effects: vibration, rubbing against other parts and excessive heat during operation.

Illustration 179	g06251598
Refer to Tooling Table for the part number of the contamination control bags.

When you have removed any component of the common rail fuel system from the engine, immediately place the protective caps onto the sealing surfaces. Then, place the whole component in a protective bag. The protective caps will prevent the sealing surfaces from contacting any other surface. The protective bag will keep the components clean during storage.

Do not clean the component immediately after the component has been removed from the engine. The residual diesel fuel will serve as a corrosion inhibitor until the component has been installed. Clean the components immediately before installation.

Service Cap Kits for the Fuel System

There are three service cap kits for the C175 fuel system. These kits will provide dealers and customers with the necessary parts for contamination control of the fuel system components during service. The caps will ensure minimal contamination of final assembly of the system.

Note: The service caps cannot be reused.

Table 5

339-9352 Cap Kit Service Cap Kit for Injectors, High-Pressure Fuel Lines, and Flow Limiter (1)
Callout	Part Number	Cap Number	Qty of Each Cap
(1)	9U-7071	16	60
(2)	9U-7088	57	120
(3)	9U-7072	17	80
(4)	9U-7084	46	60
(6)	9U-7085	53	60
(7)	9U-7077	28	120
(-)	9U-7087	-	60

(1)	Used for contamination control of the fuel system and pump when removing the cylinder heads.

Table 6

339-9354 Service Cap Kit for Common Rail
Callout	Part Number	Cap Number	Qty of Each Cap
(1)	9U-7071	16	20
(2)	9U-7088	57	40
(3)	9U-7072	17	20
(4)	9U-7084	46	24
(5)	9U-7187	-	20
(6)	9U-7085	53	21
(7)	9U-7077	28	23
(8)	9U-7080	40	6

Table 7

382-5051 Fuel Injection Pump Kit(1) (2).
Callout	Part Number	Cap Number	Qty of Each Cap
(4)	9U-7084	46	1
(6)	9U-7085	53	6
(7)	9U-7077	28	3
(8)	9U-7080	40	3
(9)	9U-7137	-	1
(10)	9U-7073	21	1
(11)	276-0731	1	1
(12)	276-0746	12	1
(13)	276-0753	49	1
(14)	9U-7082	42	4
(15)	9U-7087	55	5
(16)	9U-7081	41	1

(1)	Contains other parts that are used with the disassembly/assembly of the pump.
(2)	339-9353 Cap Kit is available as an alternative kit.

Table 8

Service Caps Used in The Low-Pressure Fuel Systems on Off-Highway Trucks (1)
Callout	Part Number	Cap Number	Qty of Each Cap
(4)	9U-7084	46	3
(6)	9U-7085	53	3
(7)	9U-7077	28	5
(14)	9U-7082	42	6
(15)	9U-7087	55	4
(16)	9U-7081	41	3
(17)	7E-8716	44	4

(1)	The caps and plugs listed in this table are not part of a kit and must be ordered individually.

Locations for Service Caps

The following images show the locations of the specific service caps on the components of the fuel system.

Service Cap Placement for the 339-9354 Cap Kit

Refer to Table 5 for a detailed parts list for the High-Pressure Fuel Lines Service Kit.

Illustration 180	g01770254
High-Pressure Fuel Line (1) 9U-7071 Cap (# 16) (2) 9U-7088 Cap (# 57)

Illustration 181	g01770474
Rail Support (2) 9U-7088 Cap (# 57) (3) 9U-7072 Cap (# 17)

Illustration 182	g01770700
Flow Limiter (4) 9U-7084 Cap (# 46) (5) 9U-7187 Cap

Illustration 183	g01902873
Cylinder Head (6) 9U-7085 Cap (# 53) (7) 9U-7077 Cap (# 28)

Illustration 184	g01771433
Injector (3) 9U-7072 Cap (# 17)

Illustration 185	g01902553
Rail End (4) 9U-7084 Cap (# 46)

Illustration 186	g01771514
Injector Return Connector (7) 9U-7077 Cap (# 28)

Illustration 187	g01771576
High-Pressure Cross Over Line (8) 9U-7080 Cap (# 40)

Illustration 188	g01771713
High-Pressure Pump Line (8) 9U-7080 Cap (# 40)

Illustration 189	g01771816
Junction Block (4) 9U-7084 Cap (# 46) (6) 9U-7085 Cap (# 53)

Illustration 190	g01771841
High-Pressure Rail Line (8) 9U-7080 Cap (# 40)

Service Cap Placement for the 382-5051 Fuel Injection Pump Kit

Refer to Table 7 for a detailed parts list for the High-Pressure Fuel Pump Service Kit.

Illustration 191	g01902078
(6) 9U-7085 Cap (# 53)

Illustration 192	g01902317
(8) 9U-7080 Cap (# 40) (9) 9U-7137 Threaded Cap (10) 9U-7073 Cap (#21)

Illustration 193	g01902514
(11) 276-0753 Cap (# 49) (12) 276-0746 Cap (# 12) (13) 276-0731 Cap (# 1)

Service Cap Placement for the 339-9354 Cap Kit

Refer to Table 6 for a detailed parts list of the Low-Pressure Fuel Systems in Electric Power Generation Service Kit.

Illustration 194	g01903455
(4) 9U-7084 Cap (# 46) (6) 9U-7085 Cap (# 53) (14) 9U-7082 Cap (# 42) (15) 9U-7087 Cap (# 55)

Illustration 195	g01903493
(6) 9U-7085 Cap (# 53) (7) 9U-7077 Cap (# 28) (15) 9U-7087 Cap (# 55) (16) 9U-7081 Cap (# 41)

Illustration 196	g01903541
(6) 9U-7085 Cap (# 53) (14) 9U-7082 Cap (# 42) (15) 9U-7087 Cap (# 55)

Illustration 197	g01913364
(7) 9U-7077 Cap (# 28) (17) 7E-8716 Cap (# 44)

Illustration 198	g01913454
(17) 7E-8716 Cap (# 44)

Illustration 199	g01773553
(4) 9U-7084 Cap (# 46)

Illustration 200	g01913475
(16) 9U-7081 Cap (# 41)

Illustration 201	g01913477
(14) 9U-7082 Cap (# 42)

Illustration 202	g01774597
(7) 9U-7077 Cap (# 28)

Illustration 203	g01914174
(15) 9U-7087 Cap (# 55)

Illustration 204	g01914194
(17) 7E-8716 Cap (# 44)

Illustration 205	g01914333
(14) 9U-7082 Cap (# 42)

Illustration 206	g01775013
(7) 9U-7077 Cap (# 28)

Service Cap Placement for the Low-Pressure Fuel Systems on Off-Highway Trucks

Refer to Table 8 for a detailed parts list of the Low-Pressure Fuel Systems on Off-Highway Trucks.

Illustration 207	g01903583
(4) 9U-7084 Cap (# 46) (6) 9U-7085 Cap (# 53) (14) 9U-7082 Cap (# 42) (15) 9U-7087 Cap (# 55)

Illustration 208	g01903614
(6) 9U-7085 Cap (# 53) (7) 9U-7077 Cap (# 28) (15) 9U-7087 Cap (# 55) (16) 9U-7081 Cap (# 41)

Illustration 209	g01903635
(6) 9U-7085 Cap (# 53) (14) 9U-7082 Cap (# 42) (15) 9U-7087 Cap (# 55)

Illustration 210	g01914533
(7) 9U-7077 Cap (# 28) (17) 7E-8716 Cap (# 44)

Illustration 211	g01914567
(17) 7E-8716 Cap (# 44)

Illustration 212	g01779873
(4) 9U-7084 Cap (# 46)

Illustration 213	g01914571
(16) 9U-7081 Cap (# 41)

Illustration 214	g01914593
Filtered fuel tube nut and bypass fuel tube nut on the 793 and 795 application (14) 9U-7082 Cap (# 42)

Illustration 215	g01914606
Filtered fuel tube nut and bypass fuel tube nut on the 797 application (14) 9U-7082 Cap (# 42)

Illustration 216	g01781774
Filtered fuel connection and bypass fuel connection on the 793 and 795 application (7) 9U-7077 Cap (# 28)

Illustration 217	g01785114
Filtered fuel connection and bypass fuel connection on the 797 application (7) 9U-7077 Cap (# 28)

Illustration 218	g01903813
Unfiltered fuel tube nut at base on the 793 and 795 application (15) 9U-7087 Cap (# 28)

Illustration 219	g01904194
Unfiltered fuel tube nut at base on the 797 application (15) 9U-7087 (# 28)

Illustration 220	g01914658
Unfiltered fuel connection at base on the 793 and 795 application (17) 7E-8716 Cap (# 44)

Illustration 221	g01914665
Unfiltered fuel connection at base on the 797 application (17) 7E-8716 Cap (# 44)

Illustration 222	g01914666
Fuel injector line nut at rail (14) 9U-7082 Cap (# 42)