Installation of New Hose Assembly for Unit Injector Hydraulic Pump{1274, 1307, 1714} Caterpillar

Cold Planer:

PM-565 (S/N: 3TK1-UP)

PM-565B (S/N: 8GS1-UP)

Landfill Compactor:

836 (S/N: 7FR1-UP)

Engine:

3408E (S/N: 7PR1-UP)

3412 (S/N: 2WJ1-UP; 38S1-UP; 81Z1-UP)

3412C (S/N: BAK1-UP; PTL1-UP; 5FL1-UP; DJN1-UP; 9EP1-UP; RLR1-UP; 8AR1-UP; 9BR1-UP; TFT1-UP; BCW1-UP; RTY1-UP; 81Z1-UP)

3412E (S/N: 4CR1-UP; BFT1-UP)

7271 (S/N: 36W1-UP)

G3412 (S/N: R7A1-UP; 7DB1-UP; 3NK1-UP; KAP1-UP)

G3412C (S/N: 6ZM1-UP; 5KR1-UP; 9RR1-UP)

Generator Set:

3412C GEN SET (S/N: BAX1-UP)

Industrial Engine:

3412C IND (S/N: 38S1-UP)

3412E IND (S/N: BDT1-UP)

Marine Engine:

3412E MARINE (S/N: 9KS1-UP; 9PW1-UP)

C30 MARINE (S/N: CLX1-UP)

C32 MARINE (S/N: RXB1-UP)

Excavator:

307B (S/N: AFB1-UP)

5110 (S/N: 7GN1-UP; 8HN1-UP)

5110B (S/N: AAA1-UP; AAK1-UP; AAT1-UP)

Motor Grader:

24H (S/N: 7KK1-UP)

Off-Highway Truck/Tractor:

69D (S/N: 9SS1-UP; 9XS1-UP)

73D (S/N: 9YS1-UP; 1GW1-UP)

769C (S/N: 01X1-UP)

769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)

773B (S/N: 63W1-UP)

773D (S/N: 7ER1-UP; 7CS1-UP)

773E (S/N: BDA1-UP)

Quarry Truck:

771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)

775B (S/N: 7XJ1-UP)

775D (S/N: 6KR1-UP; 8AS1-UP)

775E (S/N: BEC1-UP)

Petroleum Engine:

3412E PETROLEUM (S/N: Z2D1-UP)

Power Module:

PM3412 (S/N: CAJ1-UP)

Track-Type Tractor:

D10N (S/N: 2YD1-UP; 3SK1-UP)

D10R (S/N: 3KR1-UP; AKT1-UP)

D8L (S/N: 53Y1-UP)

D9L (S/N: 14Y1-UP)

D9N (S/N: 1JD1-UP; 5FJ1-UP; 6XJ1-UP)

D9R (S/N: ABK1-UP; 7TL1-UP; 8BL1-UP)

D9T (S/N: RJS1-UP)

Underground Articulated Truck:

AD40 Series II (S/N: 1YZ1-UP)

AD45 (S/N: BKZ1-UP)

AE40 II (S/N: BLW1-UP; 1ZZ1-UP)

Wheel Dozer:

834B (S/N: 7BR1-UP; 92Z1-UP)

844 (S/N: BBN1-UP; 2KZ1-UP)

Wheel Loader:

988B (S/N: 50W1-UP)

988F Series II (S/N: 2ZR1-UP)

988F (S/N: 8YG1-UP)

990 Series II (S/N: BCR1-UP; 4FR1-UP)

990 (S/N: 7HK1-UP)

Wheel Tractor-Scraper:

631D (S/N: 24W1-UP)

631E Series II (S/N: 1AB1-UP; 1NB1-UP)

631G (S/N: AWK1-UP; CLR1-UP; CMT1-UP)

633D (S/N: 25W1-UP)

633E Series II (S/N: 2PS1-UP)

637D (S/N: 26W1-UP; 27W1-UP)

637E Series II (S/N: 1FB1-UP)

637E (S/N: 1JB1-UP)

637G (S/N: CEH1-UP; CEJ1-UP; AXT1-UP)

639D (S/N: 99X1-UP)

651B (S/N: 67K1-UP)

651E (S/N: 4YR1-UP; 5XR1-UP)

657B (S/N: 68K1-UP)

657E (S/N: 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-UP; 91Z1-UP)

Introduction

The following procedures contain crucial information on correctly installing the new 162-2501 Hose As and the 258-8917 Protection Sleeve .

Note: The 162-2501 Hose As replaces 107-7942 Tube As .

Installation Procedure of the Hose Assembly

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Illustration 1	g01230674

1. Remove old 162-2501 Hose As (1). Keep all of the manifold and pump fittings attached.

Note: Step 2 is only for 3408E engines.

2. Remove the 7W-6492 Pipe Plug (2) from the aftercooler housing (3). Install the 8T-6762 Pipe Plug into the aftercooler housing.

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Illustration 2	g01230678

Note: Always tighten the fittings with your hand before you use a wrench. Support the hose and the elbow while you tighten in order to avoid the following damage: twisting, kinking and side loading.

3. Loosen elbow (4) and jam nut (5) .

4. Hand tighten the nut on the hose (5) to the elbow (4) .

5. Install the other end of the hose (6) to the pump fitting. Tighten the nut to 125 ± 15 N·m (90 ± 11 lb ft).

6. Hold the elbow (4) in position and torque the jam nut to 145 ± 15 N·m (105 ± 11 lb ft).

7. Support the elbow (4). Tighten the nut (5) on the hose to 125 ± 15 N·m (90 ± 11 lb ft).

Illustration 3	g01230687

Illustration 3 shows the routing of the 162-2501 Hose As (8). The hose is routed from the rail, around the rear of the fuel transfer pump (9), and into the 90 degree fitting (7) that is installed into the pump.

Illustration 4	g01230689

Some 3408 engines use an aftercooler that is mounted high. The mounting bracket (10) is located close to the 162-2501 Hose As (8). If there is not enough clearance to install the protective sleeve, the hose will need to be loosened and the hose will need to be repositioned. Refer to 5 for repositioning of the hose.

Illustration 5	g01230690

The hose must be realigned if any of the following conditions exist:

• Not enough clearance against the fuel transfer pump

• Not enough clearance against the support bracket

1. Loosen the end of the hose (12) .

2. Loosen the elbow and the jam nut (11).

   Note: Do not remove the hose.

3. Reposition the hose in order to acquire the desired clearance.

4. Hold the end of the hose (12). Tighten the jam nut (11) .

   Tighten the jam nut to the following torque. ... 143 ± 15 N·m (105 ± 11 lb ft)

Note: Locking pliers can be used on the crimped portion of the hose. Do not use the locking pliers on the braided portion of the hose. This will damage the hose which will cause a failure.

5. Tighten the end of the hose (12) .

   Tighten the end of the hose to the following torque. ... 125 ± 15 N·m (92 ± 11 lb ft)

   Note: If adjustment of the hose is required, make sure that the hose is not bent. Also, ensure that the hose is not twisted. If these conditions exist the PTFE liner can be damaged.

Installation of the Protective Sleeve Over the New Hose Assembly

Illustration 6	g01106118
Top view

Installation of a protective sleeve for the hoses of the pumps (1) of the HEUI Fuel System is now used. If this hose fails, there is a possibility that fuel could spray onto hot engine parts. A leak can be caused by abrasions to the surface of the hose or by damage to the braided exterior of the hose. The PTFE liner of the hose can be damaged if the hose has been bent.

Note: Do not remove the hose from the engine in order to install the protective sleeve. Install the protective sleeve with the hose on the engine.

Illustration 7	g01106117

The 258-8917 Sleeve (3) has been developed in order to fit around the 162-2501 Hose As (2) .

Note: The writing on the sleeve must be facing outward when the sleeve is installed. If a leak would occur, the sleeve would prevent the oil from spraying onto hot surfaces of the engine. The sleeve directs the oil to the "V" of the cylinder block. If the leak continues and the leak grows in volume the leak will cause decreased pressure with the pump. Issues with the engine performance will then be experienced.

Illustration 8	g01230688

Illustration 8 shows the 258-8917 Sleeve (3) once the sleeve is installed on the 162-2501 Hose As (2). After the sleeve is installed, ensure that the writing that is on the sleeve is facing outward. Slide the sleeve between the hose and the fuel transfer pump that is located at the rear of the pump. Once the sleeve is in place, be sure that the VELCRO on the sleeve is as even as possible throughout the length of the sleeve. Also, ensure that the VELCRO part of the sleeve faces downward.