Procedure to Install the New Fuel Manifold and the Fuel Lines on Certain Caterpillar Machines{1250, 1251, 1261, 1274, 1702} Caterpillar

Wheel Dozer:

844H (S/N: BTW1-UP)

Wheel Loader:

990H (S/N: BWX1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

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Fuel hose rubbing or chaffing can cause the hose to fail and leak. Failure to fully comply with this rework procedure can result in a fuel leakage and can result in a potential fire hazard, which may result in personal injury or death. Make sure that the fuel hose only contacts the mounting hardware and does not rub or touch anything else.

Note: This Special Instruction calls for the replacement of all four fuel lines that attach to the cylinder heads. Be sure to inspect all the other fuel lines for damage. This includes the hoses that deliver the fuel to the secondary fuel filter and from the secondary fuel filter.

Note: Components that are installed by the customer such as the fire suppression systems must be carefully routed away from all fuel hoses. Components should not come into contact with cables with high electrical energy as well.

Note: The fuel lines in this Special Instruction must be replaced. Still replace the fuel lines, even if the lines seem to be serviceable externally. Also replace the fuel lines even if the fuel lines have low hours. Cavitation erosion has been observed on the internal surface of the fitting on the end of the hose and the cavitation erosion is not externally visible.

Note: Ensure that proper action is taken in order to avoid contamination of the fuel system.

Note: Some components have been removed in the illustrations in this Special Instruction for clarity.

Required Parts

Table 1

Quantity	Part Number
4	1P-1376 Port Connectors
2	090-8635 Spacers
2	0S-1571 Bolts
1	0S-1590 Bolt
2	0S-1619 Bolts
1	127-5447 Spacer
1	152-8254 Spacer
6	214-7568 O-Ring Seals
1	228-7381 Check Valve Gp
1	238-4664 Stud
1	314-3173 Manifold
1	299-9606 Plate As
2	2R-6806 O-Ring Connectors
1	322-7615 Hose As
1	322-7617 Hose As
2	322-7616 Hose As
1	304-3588 Bracket
1	314-3174 Bracket As
1	3B-1915 Bolt
1	8L-2786 O-Ring Seal
1	3S-1546 Full Nut
9	5M-2894 Hard Washers
3	5P-8244 Hard Washers
6	7V-6571 Grommets
2	7X-0440 Bolts
3	8S-9191 Bolts
6	8T-1889 Clips
6	8T-1890 Clips
2	8T-4224 Hard Washers
2	8T-9382 Bolts
1	9M-8406 Clip
1	9S-8005 O-Ring Plug
5	9S-8752 Full Nuts
10	9X-6458 Hard Washers
2	6L-2479 Braces
1	3K-1470 Spacer
2	0L-1351 Bolts
1	0S-1591 Bolt
1	1A-2029 Bolt
4	5P-7468 Clips
4	5P-7469 Clips
4	8T-9518 Grommets
4	8T-4121 Hard Washers
4	8T-4195 Bolts
1	315-6122 Hose As
1	9R-2613 Weld Boss
1	127-9258 Connector

Subassembly of the New Fuel Manifold

Illustration 1	g01445276
(1) 314-3173 Manifold (2) 2R-6806 O-Ring Connector (3) 214-7568 O-Ring Seal (4) 9S-8005 O-Ring Plug (5) 8L-2786 O-Ring Seal (6) 228-7381 Check Valve Gp

1. Assemble the two 2R-6806 O-Ring Connectors (2) and the two 214-7568 O-Ring Seals (3) on the new 314-3173 Manifold (1). Tighten the 2R-6806 O-Ring Connector to 34 ± 3 N·m (25 ± 2 lb ft).

2. Assemble the 9S-8005 O-Ring Plug (4) and the 8L-2786 O-Ring Seal (5) into the side of the fuel manifold. This is shown in Illustration 1. Tighten the 9S-8005 O-Ring Plug to 35 ± 3.5 N·m (26 ± 3 lb ft).

3. Assemble the 228-7381 Check Valve Gp (6) into the back of the fuel manifold. Tighten the 228-7381 Check Valve Gp to 115 ± 10 N·m (85 ± 7 lb ft).

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Illustration 2	g01445277
(7) 299-9606 Plate As (8) 5M-2894 Hard Washer (9) 0S-1619 Bolt (10) 9S-8752 Full Nut

4. Assemble the fuel manifold to the 299-9606 Plate As (7). Use four 5M-2894 Hard Washers (8), two 0S-1619 Bolts (9), and two 9S-8752 Full Nuts (10) to secure the manifold. Tighten the 9S-8752 Full Nuts to 47 ± 9 N·m (35 ± 7 lb ft).

Procedure to Remove the Old Fuel Manifold

Note: Make sure that any debris is cleaned thoroughly from the engine before disassembling any fuel lines. Keep all fuel lines capped in order to prevent any dirt from entering the fuel lines. Make sure that the fuel lines do not have any interference once the fuel lines are reinstalled.

Illustration 3	g01445279
237-4895 Manifold (1) Fuel hoses that connect to the old fuel manifold. (2) Mounting bolts for the old fuel manifold

1. Disconnect the fuel hoses (1) from the old fuel manifold.

2. Remove the three mounting bolts (2) that secure the old fuel manifold.

Procedure for Installing the New Fuel Manifold

Installing the New Fuel Manifold on the Engine

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NOTICE
Move the hose from side to side after the installation of any hose is complete. The hose should not touch anything. If so, adjust the hose so the hose will not touch or rub on anything on the engine or in the engine compartment.

Illustration 4	g01445280
314-3173 Manifold (1) 6V-9831 Cap As (2) 8L-2746 O-Ring Seal , 127-9258 Connector , and 8L-2786 O-Ring Seal (3) 9X-6458 Hard Washer , and 8S-9191 Bolt

1. Install the new fuel manifold. Refer to Illustration 4 for the proper orientation. Secure the new fuel manifold with three 8S-9191 Bolts , and with three 9X-6458 Hard Washers (3). Tighten the 8S-9191 Bolts to 47 ± 9 N·m (35 ± 7 lb ft).

2. Install a 127-9258 Connector , a 8L-2786 O-Ring Seal , and a 8L-2746 O-Ring Seal (2) on the new fuel manifold. Temporarily install a 6V-9831 Cap As on the fuel manifold.

Rework on the Right Rear Fuel line

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NOTICE
Move the hose from side to side after the installation of any hose is complete. The hose should not touch anything. If so, adjust the hose so the hose will not touch or rub on anything on the engine or in the engine compartment.

Illustration 5	g01445281

1. Remove the nut, washers, the clip, and the studbolt (4) and discard the nut, washers, the clip, and the studbolt.

2. Remove the studbolt, and the washer (5) and discard the studbolt, and the washer.

3. Remove the nut, the washers, the clip, and the studbolt (6) and discard the nut, washers, the clip, and the studbolt.

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Illustration 6	g01445282
Old port connector

4. Remove the hose coupling from the port connector (7). Discard the hose.

5. Remove the 030-7937 Port Connector (8) from the cylinder head. Discard the 030-7937 Port Connector and the O-ring seal.

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Illustration 7	g01445283
New port connector (9) 1P-1376 Port Connector

6. Install the new 1P-1376 Port Connector (9) on the cylinder head. Use a new 214-7568 O-Ring Seal when you install the new port connector to the cylinder head. Tighten the 1P-1376 Port Connector to 34 ± 7 N·m (25 ± 5 lb ft).

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Illustration 8	g01445284
(10) 090-8635 Spacer (11) 5M-2894 Hard Washer (12) 0S-1571 Bolt (13) 304-3588 Bracket (14) 7X-0440 Bolt , and 8T-4224 Hard Washer

7. Install two 090-8635 Spacers (10), a 304-3588 Bracket (13), two 5M-2894 Hard Washers (11), and two 0S-1571 Bolts (12). Tighten the 0S-1571 Bolts to 47 ± 9 N·m (35 ± 7 lb ft).

8. Install a 7X-0440 Bolt and a 8T-4224 Hard Washer (14) on the valve cover. Tighten the 7X-0440 Bolt to 25 ± 6 N·m (18 ± 4 lb ft). Refer to Illustration 8 for the proper location of the bolts.

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Illustration 9	g01445285
(15) 8T-1889 Clip (16) 8T-1890 Clip (17) 7V-6571 Grommet (18) 3S-1546 Full Nut (19) 5P-8244 Hard Washer (20) 8T-9382 Bolt

9. Connect the 322-7617 Hose As to the connector and the fuel manifold. Just hand tighten the hose.

10. Install 8T-1889 Clip (15), 8T-1890 Clip (16), 7V-6571 Grommet (17), 3S-1546 Full Nut (18), 5P-8244 Hard Washer (19), and 8T-9382 Bolt (20). Tighten the 8T-9382 Bolt to 70 ± 15 N·m (52 ± 11 lb ft).

Note: The opening in the 7V-6571 Grommet must line up in the gap between the 8T-1889 Clip and the 8T-1890 Clip .

11. Tighten the coupling for the 322-7617 Hose As at the connector to 27 ± 6 N·m (20 ± 4 lb ft).

12. Tighten the coupling for the 322-7617 Hose As at the manifold to 27 ± 6 N·m (20 ± 4 lb ft).

Rework on the Left Rear Fuel Line

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NOTICE
Move the hose from side to side after the installation of any hose is complete. The hose should not touch anything. If so, adjust the hose so the hose will not touch or rub on anything on the engine or in the engine compartment.

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Illustration 10	g01445286

1. Remove the 1B-2578 Nut , 5M-2894 Hard Washer , 174-5907 Clip , 9X-6458 Hard Washers , and 7N-1637 Stud (21). Discard all the parts that were just removed.

2. Remove the 7N-1637 Stud and the 9X-6458 Hard Washers (22). Discard the stud and the washers as well.

3. Remove the 5S-0003 Nut , 9M-1974 Hard Washer , 183-4403 Clip , 3E-4352 Hard Washer , and the 224-9907 Stud (23). Discard all the parts that were just removed.

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Illustration 11	g01445287

4. Remove the hose coupling from the port connector (24). Discard the hose.

5. Remove the 030-7937 Port Connector (25) from the cylinder head. Discard the port connector and the O-ring seal.

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Illustration 12	g01445288

6. Install the 1P-1376 Port Connector and the 214-7568 O-Ring Seal (26) into the cylinder head. Tighten the 1P-1376 Port Connector to 34 ± 7 N·m (25 ± 5 lb ft).

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Illustration 13	g01445289

7. Install the 3B-1915 Bolt , and the 9X-6458 Hard Washer (27). Tighten the 3B-1915 Bolt to 47 ± 9 N·m (35 ± 7 lb ft).

8. Install the 7X-0440 Bolt , and the 8T-4224 Hard Washer (28) on the valve cover. Tighten the 7X-0440 Bolt to 25 ± 6 N·m (18 ± 4 lb ft).

9. Connect the 322-7615 Hose As to the connector and to the fuel manifold. Just hand tighten the hose at the connector and the fuel manifold.

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Illustration 14	g01445290
(29) 8T-1889 Clip (30) 8T-1890 Clip (31) 7V-6571 Grommet (32) 127-5447 Spacer (33) 0S-1590 Bolt and 9X-6458 Hard Washer (34) 314-3174 Bracket As (35) 8T-9382 Bolt and 5P-8244 Hard Washer

10. Install the 0S-1590 Bolt and the 9X-6458 Hard Washer (33). Install the 127-5447 Spacer (32), and the 314-3174 Bracket As (34). Tighten the 0S-1590 Bolt to 47 ± 9 N·m (35 ± 7 lb ft).

11. Install the 8T-1889 Clip (29), 8T-1890 Clip (30), 7V-6571 Grommet (31), 8T-9382 Bolt , and the 5P-8244 Hard Washer (35). Tighten the 8T-9382 Bolt to 70 ± 15 N·m (52 ± 11 lb ft).

Note: The opening in the 7V-6571 Grommet must line up in the gap between the 8T-1889 Clip and the 8T-1890 Clip .

12. Tighten the coupling for the 322-7615 Hose As at the connector to 27 ± 6 N·m (20 ± 4 lb ft).

13. Tighten the coupling for the 322-7615 Hose As at the manifold to 27 ± 6 N·m (20 ± 4 lb ft).

Rework of the Right Front Fuel Line

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NOTICE
Move the hose from side to side after the installation of any hose is complete. The hose should not touch anything. If so, adjust the hose so the hose will not touch or rub on anything on the engine or in the engine compartment.

Illustration 15	g01445291

1. Remove the bolt, the washer, the spacer, and the clips (36). Discard the lower clip on the fuel line only.

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Illustration 16	g01445293

2. Remove the hose from the port connector and the tee (37). Discard the hose.

3. Remove the 030-7937 Port Connector from the cylinder head (38). Discard the 030-7937 Port Connector and the seal O-ring.

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Illustration 17	g01445294

4. Install the 1P-1376 Port Connector and the 214-7568 O-Ring Seal (39) into the cylinder head. Tighten the 1P-1376 Port Connector to 34 ± 7 N·m (25 ± 5 lb ft).

5. Connect the 322-7616 Hose As to the 1P-1376 Port Connector and the tee. Just hand tighten the 322-7616 Hose As .

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Illustration 18	g01445295
(40) 6L-2479 Brace , 5M-2894 Hard Washer , and 0L-1351 Bolt (41) 8T-1889 Clip (42) 8T-1890 Clip (43) 7V-6571 Grommet (44) 1A-2029 Bolt , 9X-6458 Hard Washer , and 9S-8752 Full Nut

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Illustration 19	g01445296
(41) 8T-1889 Clip (42) 8T-1890 Clip (43) 7V-6571 Grommet (45) 9S-8752 Full Nut , and 5M-2894 Hard Washer (46) 9M-8406 Clip (47) 152-8254 Spacer (48) 238-4664 Stud , and 9X-6458 Hard Washer

6. Install the bracket, the bolt, and the washer (40). Install the bolt and washer (48). Install the clips (41) and (42), and the grommet (43). Tighten the bolts to 47 ± 9 N·m (35 ± 7 lb ft).

7. Install the spacer (47), the clip (46), the nut, and the washer (45). Tighten the nut to 47 ± 9 N·m (35 ± 7 lb ft).

8. Install the bolt, two washers and the nut (44) .

Note: The opening in the 7V-6571 Grommet must line up in the gap between the 8T-1889 Clip and the 8T-1890 Clip .

9. Tighten the coupling for the 322-7616 Hose As at the connector to 27 ± 6 N·m (20 ± 4 lb ft).

10. Tighten the coupling for the 322-7616 Hose As at the manifold to 27 ± 6 N·m (20 ± 4 lb ft).

Rework on the Left Front Fuel Line

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NOTICE
Move the hose from side to side after the installation of any hose is complete. The hose should not touch anything. If so, adjust the hose so the hose will not touch or rub on anything on the engine or in the engine compartment.

Illustration 20	g01445297

Illustration 21	g01445298

1. Remove the bolt, the washer, and the clip (49). Discard the clip for the fuel line only.

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Illustration 22	g01445299

2. Remove the hose coupling from the port connector and the tee (50). Discard the hose.

3. Remove the 030-7937 Port Connector (51) from the cylinder head. Discard the 030-7937 Port Connector and the O-ring seal.

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Illustration 23	g01445300

4. Install the 1P-1376 Port Connector and the 214-7568 O-Ring Seal (52) into the cylinder head. Tighten the 1P-1376 Port Connector to 34 ± 7 N·m (25 ± 5 lb ft).

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Illustration 24	g01445301
(53) 8T-1889 Clip (54) 8T-1890 Clip (55) 7V-6571 Grommet (56) Washer that was removed in Step 1 (57) Bolt that was removed in Step 1 (58) 6L-2479 Brace (59) 5M-2894 Hard Washer (60) 0L-1351 Bolt (61) 0S-1591 Bolt (62) 9X-6458 Hard Washers (63) 3K-1470 Spacer (64) 9S-8752 Full Nut

5. Connect the 322-7616 Hose As to the 1P-1376 Port Connector and the tee connector. Only hand tighten the 322-7616 Hose As to the port connector.

6. Install the 8T-1889 Clip (53), 8T-1890 Clip (54), and the 7V-6571 Grommet (55) on the fuel hose. Reinstall the bolt and the washer. The bolt and the washer were removed in Step 1.

Note: The opening in the 7V-6571 Grommet must line up in the gap between the 8T-1889 Clip and the 8T-1890 Clip .

7. Tighten the coupling for the 322-7616 Hose As at the connector to 27 ± 6 N·m (20 ± 4 lb ft).

8. Tighten the coupling for the 322-7616 Hose As at the manifold to 27 ± 6 N·m (20 ± 4 lb ft).

Rework to the Muffler Bracket

Note: Make sure that any debris is cleaned thoroughly from the engine before disassembling any fuel lines. Keep all fuel lines capped in order to prevent any dirt from entering the fuel lines. Make sure that the fuel lines do not have any interference once the fuel lines are reinstalled.

Illustration 25	g01445302

1. Turn the electrical disconnect to the OFF position.

2. Turn the fuel shutoff valve to the OFF position.

3. Remove the hood and mufflers. Refer to Disassembly and Assembly, RENR8808, "844H Wheel Dozer and 990H Wheel Loader Engine Supplement " for the proper procedure to remove the hood and the mufflers.

4. Remove the muffler brackets once the hood and the mufflers are removed.

5. Disconnect all the fluid lines that may interfere with removing the muffler bracket.

Rework to the Muffler Bracket

Illustration 26	g01445303
Muffler Bracket (1) Location for the 9R-2613 Weld Boss (2) Area of material that needs to be removed from the muffler bracket

Illustration 27	g01445304
Muffler Bracket (A) R 37.5° (B) 60.6 mm (2.4 inch) (C) 13° (D) 30° (E) 164.2 mm (6.5 inch) (F) 188.1 mm (7.4 inch) (G) 352.4 mm (13.8 inch) (3) Old profile

The material in Area (2) in Illustration 26 must be removed from the muffler bracket. Refer to Illustration 27 for all the dimensions for removing the material from the muffler bracket.

Illustration 28	g01445305
(H) 61 mm (2.4 inch) (1) 9R-2613 Weld Boss (4) The lifting eye that is already on the muffler bracket

Install the 9R-2613 Weld Boss (1) on the existing muffler bracket. Refer to Illustration 28 for the proper location in order to install the 9R-2613 Weld Boss .

Illustration 29	g01445306
(5) 315-6122 Hose As (6) 5P-7469 Clip (7) 8T-9518 Grommet (8) 8T-4195 Bolt (9) 5P-7468 Clip (10) 8T-4121 Hard Washer

Illustration 30	g01445307

Install the hose as in Illustration 29 and Illustration 30.

Illustration 30 shows the muffler bracket with all the modifications that are listed above.